how to repair a rusty fuel tank

by Tad Roob Published 3 years ago Updated 2 years ago

Fix a Rusty Fuel Tank

Wax the Tank. Take a moment and wax the surface of the tank especially near the gas cap and near the petcock valve (double coat).
After Draining Take a Look... I took a couple of pictures to show. ...
Next Rinse With Water. ...
Seal the Holes. ...
Pour in the Metal Ready. ...
Dry the Interior. ...
Now for the Tank Sealer. ...
Swish the Tank Sealer. ...
Drain the Sealer. ...

More items...

Full Answer

How do you remove rust from a fuel tank?

What Cleans Rust Out of the Gas Tank?

Evapo-Rust The Original Super Safe Rust Remover. This product is an environmentally safe product that can help you remove rust in your gas tank that works within a couple of ...
WD-40 Specialist Rust Remover Soak. ...
OXALIC ACID 99.6% 2 Lb. ...
POR-15 40704 Rust Remover. ...
JENOLITE Original Rust Remover. ...
POR-15 49216 Fuel Tank Sealer. ...

How to remove rust from a fuel tank?

How to get rust out of diesel fuel tank?

Remove the fuel tank.
Remove the dust and debris from the outer surface.
Take a bucket and mix dishwashing soap with warm water.
Wash the outer surface thoroughly with soapy water. Don’t waste time letting it dry. ...
Get the water out. Again, pour vinegar inside the tank. ...
Lastly, pour denatured alcohol inside using a funnel. ...

How to repair a fuel tank?

Two-part epoxy putty reinforced with steel particles for lasting repairs
The epoxy takes only 5 minutes to set and cures within an hour
This epoxy can be molded, shaped, sanded, drilled, and tapped

How to clean the fuel tank?

How to Properly Clean a Gas Tank

Drain. Drain fuel tank into an approved container.
Clean Outside of Tank. Clean rust and debris from the top of the fuel tank.
Remove Fuel Pump. Remove the fuel pump from the tank.
Swirl. Swirl gas tank, pour out remaining gas and debris.
Clean Inside of Tank. ...
Swirl Again. ...
Drain and Dry. ...
Inspect. ...
Check if Dry. ...
Refill. ...

Can you repair a rusty fuel tank?

If your fuel tank has rust there are two ways fix the problem: Replace the tank with a new one or take steps to clean the inside of the tank, remove the rust, and seal the inside with a fuel tank sealer.

How do you seal an old rusty gas tank?

0:397:45How to Use the Gas Tank Sealer Kit - Gas Tank Rust Treatment - EastwoodYouTubeStart of suggested clipEnd of suggested clipAlso you get some fast etch that's going to work as a supplementary rust eater. And it's going toMoreAlso you get some fast etch that's going to work as a supplementary rust eater. And it's going to leave a zinc phosphate coating in the tank. So you can let it sit in fast etch without oxidation.

Can you use CLR to get rust out of a gas tank?

Works amazingly well. I usually leave it in for about 36 hours. I flush the empty tank with a hose, then fill it with a mild degreaser/water soloution. Shake for a few minutes, then drain and rinse well.

How do you fix a metal fuel tank?

8:3114:02How to Repair a Leaking Metal Fuel Tank Without Welding - YouTubeYouTubeStart of suggested clipEnd of suggested clipApply the sealant to a piece of cardboard. And then apply it on the tank. I'm using a mixing stickMoreApply the sealant to a piece of cardboard. And then apply it on the tank. I'm using a mixing stick for now this product is thick and extremely sticky. So it does take some patience.

How do you recoat the inside of a gas tank?

1:018:34How to RESTORE and COAT a FUEL TANK with RED KOTE. - YouTubeYouTubeStart of suggested clipEnd of suggested clipI used rust-oleum aircraft stripper it makes that job pretty easy and finally once I get all theMoreI used rust-oleum aircraft stripper it makes that job pretty easy and finally once I get all the rust out I used red coat fuel tank liner. I'll never have to worry about rust in my tank again.

Can you repair a fuel tank?

Unless the gas tank has already been removed from the vehicle, you can't repair it without getting underneath it. Most leaks are visible from the underside and can easily be patched up.

How long can you leave vinegar in a gas tank?

Using vinegar to flush rust out of the tank If there are even tiny particles left in your garage after filling up, then the odds are good they'll end up inside one way or another. To remove any leftover gasoline residue, fill the tank with vinegar and let it sit for between 12-24 hours.

How long does CLR take to remove rust?

two minutesApply directly to the stain with a brush, cloth or sponge. After 2 minutes rinse promptly with cold water. Never leave CLR Calcium, Lime and Rust Remover on an area for longer than two minutes. If the stain does not disappear, repeat this process and add more CLR Calcium, Lime and Rust Remover solution as necessary.

How do you clean a gas tank that has been sitting for years?

After removing the tank, you'll want to take a pressure washer and spray down the inside of the tank. This will help dislodge dirt, debris, and small flakes of rust. It will also help rinse out gasoline sediment. Use a pressure washer or a regular garden hose and sprayer to clean the inside of the tank.

Can you use JB weld on a fuel tank?

Supplies. JB Weld also makes a gas tank repair kit, which consists of a tube of epoxy putty, fiberglass cloth, sandpaper, and an applicator. This repair is the same as the SteelStik, but adds some additional strength with the fiberglass. This is best used in larger repairs or on a tank with multiple pinhole leaks.

Can I use JB Weld on a metal gas tank?

Includes Epoxy Putty, Fiberglass Cloth, Sandpaper, And Applicator. Versatile & Dependable: Great For Gas Tanks, Metal Tanks, Oil Pan Repairs And More. Professionals, Mechanics And Avid Diyers Know J-B Gets The Job Done.

What is the best thing to patch a gas tank?

The Versachem Heavy Duty Fuel Tank Repair Kit permanently repairs gasoline and diesel fuel tank leaks in less than 20 minutes. Use it to repair pinholes, rust-outs, hairline cracks and holes up to 1/2" in diameter. Resistant to water, gasoline, diesel and kerosene.

What can be used to seal gas tank?

POR-15 Fuel Tank Sealer is a high-tech sealer impervious to all fuels, including the new Stage II fuels which have a higher alcohol content, and additives. It has superior strength and fuel resistance. POR-15 Fuel Tank Sealer stops rust, corrosion, and fuel leaks.

How do you seal an outside gas tank?

0:065:45How To Seal A Gas Tank with KBS Tank Sealer - YouTubeYouTubeStart of suggested clipEnd of suggested clipIn this video we'll show you how to seal a fuel tank using kbs tank sealer. All right now we haveMoreIn this video we'll show you how to seal a fuel tank using kbs tank sealer. All right now we have another gas tank that here that we're going to work on uh we've already done the cleaning.

How do you seal a leaking gas tank?

Step 1 - Jack up the Vehicle. ... Step 2 - Find the Leak or Hole in the Gas Tank. ... Step 3 - Sand the Leaky Area of the Tank. ... Step 4 - Clean the Surface. ... Step 5 - Mix the Epoxy. ... Step 6 - Shape and Apply the Epoxy. ... Step 7 - Insert the Epoxy in the Hole. ... Step 8 - Fill the Tank with Gas.

Is a rusty fuel tank bad?

Rust particles in the gas tank may break free, travel into the fuel lines or injectors, and cause the engine to malfunction because there isn't enough fuel to mix with air. Rust can also invade the fuel filter and hamper fuel flow.

Step 1: Wax the Tank

Take a moment and wax the surface of the tank especially near the gas cap and near the petcock valve (double coat). The chemicals and sticky tape stuff will come off easier. and it will help protect if something splashes onto the paint. The fuel and chemicals are really pretty tame but it definitely will help if you do this step

Step 2: After Draining Take a Look..

I took a couple of pictures to show. It didn't seem Terrible but still pretty bad for anything that could get past the fuel filter and into the tiny jets of the carburetors. We did experience some engine cut outs when the fuel tank got pretty low on fuel. There was some on the screens of the the petcock valve as you can see.

Step 3: Next Rinse With Water

So I took a small trash can and covered it with an old t-shirt. I had a yard trash Bungee type band I got from a christmas stocking that did the trick. With the tank cap off and the petcock valve removed, I simply rinsed with the water hose capturing the remnant gas and particles into the trash can filter.

Step 4: Seal the Holes

I used Gorilla tape to seal the openings. Start with the petcock hole. Dry the petcock area to be sealed up so that the tape will stick. One layer with 1" overlap did the trick for me. Really rub around the openings to seal well. The petcock hole was easier since much of the surface is flat near the opening.

Step 5: Pour in the Metal Ready

I pulled off both tape covers and drained the marine clean . I captured the first rinse in a trash can so that I could dispose of properly. The rest I rinsed out onto the drive -- it did not seem to stain. My son who is taking chemistry felt that the ingredients were pretty benign. I guess you could look up the MSDS details.

Step 6: Dry the Interior

After the Marine-clean and Metal ready swish/rinses are done then it is time to dry the tank. really shake it in all angles to get any large pockets of water out. By now you are becoming an expert at figuring out where the water is (without being able to see it).

Step 8: Swish the Tank Sealer

I swished for the entire time limit described in the directions (2 hours). After I was sure it would not leak I brought the tank inside to watch TV while I rotated it in all directions coating every inch of the interior. Remember "be the liquid" . Coat every where on the inside.

How to fix a gas tank?

Step 1 – Park Your Vehicle in a Safe Location. A gas tank repair could go wrong if necessary safety precautions are not taken first. Start off by parking the car in a clutter-free environment, away from any flammable substances. Make sure the area is also well-ventilated.

How to get rid of rust on a car?

Get rid of some chunks by spraying a pressure washer directly into the fuel tank. Follow it up with some hot soapy water.

How long to let acid sit in fuel tank?

Next, pour an equal amount of acid into the water inside the tank. Make sure the acid doesn't fall on the outer surface. Let the water and acid mixture rest for 30 minutes to an hour. After that, drain the liquid out of the fuel tank.

How to neutralize acid in a water tank?

After removing the acid from the tank, it is important to neutralize the tank. Introduce a mixture of 1/4 cup of baking soda and two gallons of clean water into the tank. Let it rest for a little while, and repeat the same process at least six times to ensure there is no acid remaining.

Where is the fuel supply line?

The first one is the supply line, which originates from the bottom of the tank and heads to the engine. The second is the fill tube that originates from the gas entry point, and the last one is the vent line. Don't forget the fuel sender wires.

Is rust removal good for you?

Muriatic acid, or hydrochloric acid, works as a good rust removal agent. Be extremely cautious while using this product. The fumes released during the interaction of the acid and the rust are extremely harmful, so make sure you are wearing protective clothing, eye wear, gloves, and a facemask to stay safe. Keep the fire extinguisher within reach as well.

Can steel fuel tanks rust?

Sooner or later, all steel fuel tanks are likely to have the same problem. They will begin to rust, flake and develop pinhole leaks. But there's an inexpensive way to repair old tanks, says Gackle, N. Dak. farmer Roger Gutschmidt.

Can Gutschmidt run into fuel line?

You can't let the product run into a fuel line and if you have a shut off valve in the bottom of your tank, you have to take that out and screw a pipe plug into its place.". Gutschmidt let the product dry for 24 hrs. before reinstalling the tank into the tractor.

How to clean rust from gas tank?

Fortunately, there are multiple ways to clean rust out of a gas tank, including abrasives, chemicals, and even electrolysis.

What is needed to remove rust from gas tank?

You need equipment such as a 12V battery, a piece of ferrous metal (such as iron), and sodium carbonate. Performing electrolysis to remove rust is useful for smaller objects, but with some modifications, you can use the method to remove rust from a gas tank, too. It’s important to exercise caution when connecting and disconnecting the power source, ...

What is the best way to remove rust from a car?

Although technically vinegar is a chemical, it’s not as heavy-duty as other chemical options for rust removal. You can also use phosphoric, hydrochloric, acetone, or muriatic acid as the chemical abrasive.

How to remove rust from a tank?

The safest method of chemical rust removal involves mixing vinegar and baking soda to fill (or nearly fill) the tank. Let the mixture sit until it bubbles up and begins to change color with the rust particles. Then rinse thoroughly to ensure it’s completely empty.

What are the safety precautions for gas tanks?

Safety Precautions When Working with Gas Tank Treatments. Many rust treatments for gas tanks involve harsh chemicals or abrasives. When working with any chemicals, plus fuel, you should avoid breathing in the products and protect your face while working.

What are the negative effects of rust in a gas tank?

Negative impacts of rust in the gas tank include: ● Inconsistent fuel flow, which can affect acceleration as well as your vehicle’s idling state. ● Plugged up fuel filters and lines, which could cause pressure buildup or worse.

How to get gravel out of gas tank?

Most recommendations include using a liquid—whether water or a combination of soap and water— to help swish the abrasive material around and dislodge the rust particles.

Step 1 – Park Your Vehicle in A Safe Location

Step 2 – Drain The Gas

Step 3 – Remove The Fuel Lines

Step 4 – Remove The Metal Straps

Step 5 – Remove Loose Rust

Once the fuel tank is out of the vehicle, you can start with the rust removal process. However, before you introduce the rust remover, try and get rid some of the loose rust first. Get rid of some chunks by spraying a pressure washer directly into the fuel tank. Follow it up with some hot soapy water. Pour it inside and let it sit in the tank for s...