Did a final test on tank this weekend. Took it up to 4psi. Lost that in one hour. Took out interior tonight and will probably start on removing tank this weekend.

Carpet up and tank is empty. Going to fill with water and drain a couple times. Hope to have tank exposed over the weekend.

When I removed my tank, I cut along the inside edge of the stringers on each side of the tank. After digging thru all the foam I got the tank out and discovered there was a screw laying under the tank. Took it abt 15 years to rub thru and cause a leak. Found a welder that would weld an alum gas tank (that wasn't easy) and he welded it and press tested tank. After tank was back in, I glued, screwed and glassed some 1 X 1's to the inside edges of the stringers and re-used the portion of the floor I cut out (it was still in great shape). Glued,screwed and glassed the floor portion back in, lay'ed the carpet back down and walah. That was abt 15 years ago and it's still good.
Digging out the foam was the hardest part..

Well I got the tank out today. No foam holding it in which was great.

Did you find the leak ?

Yes.

Have same problem. Who makes new ones? 100 Gal.

I got mine made locally. Patriot Marine. Great work.

Where was the leak? What was the root cause?

starting this exact same project this weekend in my tantrum . makes me feel better to see someone else not afraid to do this themselves .