I will skin my ignorance here, since I have never looked in a OWB. Isnt the tank replaceable. I would think that if the tank started leaking it would either be because of a defect, or corrosion. A defect would be a crack at a seam or joint and should be easy to repair with a good welder. Corrosion would be a whole different issue. If there has been enough corrosion to work thru the tank, I would tend to believe the entire tank would be corroded and not just one little spot where it is leaking. Are the tanks not glass lined like a hot water heater tank? If so, any welding will destroy the glass lining. Fixing a rusted spot might give you a few more years of use, but sooner or later a new leak would appear in a different location. Also any welded spot will rust really fast and a new leak could start at the weld seam. Is the tank exposed to the fire in the stove. I would think not, most likely there are boiler tubes getting the bulk of the heat and hot water flows thru the tubes to the tank. Like I said, I am ignorant as to how a OWB heats water, but I would think any corrrosion issues in the tank would also be found in the boiler tubes that feed the tank. What kind of steel is used in making the boiler tank. If it is stainless, a gas purge would need to be used to prevent the welding procedure from burning off the chrome and nickle in the stainless on the backside of the weld. For a big size tank, this would be difficult and expensive. If your welder isnt using a purge, he isnt as good a welder as you think he is. If the tank is not stainless, then the purge would not be necessary. Simply running a bead on the outside of the tank is not a fix, and only a patch at best. Also, cutting out and replacing the rusted metal probably isnt the best option. Welding a patch covering the leak would seem to be a better, not to mention easier, fix. At ay rate, if the tank is replaceable, I would think a new tank should cost less that the $1000 mentioned repair cost.