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I would try to go with the Moeller poly tanks. The best stock size you can fit. This is what I did last year. Really can't beat it for the money. Once you start talking custom aluminum your talking some bucks.
Can you move the tank around any. Or put 2 in the place of one?
I have seen aluminum tanks waste away from outside with localised oxidation spots more than from the inside.
Definitely do everything since you have it out, new vent, fill, supply lines....alcohol free of course.
Plastic is the best choice when dealing with ethonol. Aluminum from what I have read with ethanol over time may be an issue too.
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