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Fuel tank sealing on a custom aluminum catamaran build defeats multiple gasket attempts before a working solution emerges in part 20 of the SV Delos build series. Brian spends several days chasing an airtight seal on the diesel tanks, cycling through neoprene rubber (rejected as neither fuel-safe nor petroleum-resistant), then nitrile rubber gaskets, before discovering the real failure point: nylon washers deforming under torque and stainless steel bolts requiring Teflon tape that compromised the seal.19:25 The fix combines homemade aluminum square washers cut from spare plate, 6061 aluminum bolts to eliminate galvanic corrosion risk, and compressible fuel-resistant fiber washers beneath the aluminum washers. Pressure-testing with soapy water and a gauge confirms the seal holds. Separately, the team cuts recessed anode pockets into both hulls, choosing aluminum anodes over zinc for their lighter weight, higher electrochemical capacity, and suitability across salt, brackish, and fresh water — while noting that passivation buildup requires regular cleaning or the anodes stop working. Welder Kurt departs the build team at the episode's close. The tank-sealing lesson: nylon washers crush under bolt torque and allow leaks; aluminum washers with fiber washers underneath provide the consistent clamping pressure an aluminum tank lid needs.

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