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Anybody Know of anyone competent at welding fuel tanks???

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K2-K6:
If it's porous over a small area then brasing can usually get it quite well, some decent flux and well wired brushed first allows it to flow nicely.

The fumes problem is easy, just get a pipe onto car exhaust and poke it into the tank to make it inert.

You can get a "putty" (not sure of the name) that you put onto the painted outside to stop heat build-up in the outer surface, I've seen welding done this way without any affect to the paint but you have to do it a bit at a time to avoid building up too much heat.

Just a bit off beam but just read about a process of Flame spraying using zinc to repair old panels for classic vehicles etc that could be suitable for your needs. There are various contact details in the magazine if you need any.

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