Ameer Randolph
Fiberglass fuel tanks are a viable option for gasoline tanks, especially for antique engines. The process involves cleaning the tank, cutting the fiberglass to fit the tank, and applying coats of resin. However, it's important to note that ethanol-enhanced gasoline can react with the fiberglass and resin, leading to potential engine issues. Gasoline with ethanol has been observed to dissolve fiberglass fuel tanks, creating a black sludge that can destroy engines. Therefore, caution must be exercised when considering the use of fiberglass fuel tanks with certain types of gasoline.
| Characteristics | Values |
|---|---|
| Materials | Fiberglass, resin, cloth, paint, wire brush, grinder |
| Preparation | Clean the tank with a wire brush and grinder, cut fiberglass to fit the tank, mix resin |
| First Coat | Paint a thin coat of resin on the tank, let it dry (time varies with temperature and ventilation) |
| Second Coat | Apply a heavy coat of resin, immediately put on the cloth, saturate the cloth with resin, work out air bubbles, let it dry |
| Subsequent Coats | Apply additional coats as needed to achieve a smooth finish, let each coat dry |
| Finishing | Sand or grind off any rough spots, feather the edges of the fiberglass, paint the tank |
| Caution | Resin has a strong odor, work in a well-ventilated area, ethanol can dissolve fiberglass fuel tanks and cause engine issues |
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Prepare the tank
To prepare the tank for fibreglassing, the first step is to ensure the tank is very clean. Using a wire brush on a grinder is an effective method to clean the outside of the tank. Next, cut the fibreglass to fit the tank. The cloth can be cut to cover the bottom and up the sides in one piece by making cuts at the corners. It is recommended to cover the bottom and about halfway up the sides. For irregular and round tanks, you may need to cut one piece for the bottom and additional pieces for the sides. Overlap any cuts by about half an inch.
Once the cloth is cut, set it aside and mix the resin. Follow the mixing directions provided with the resin, as formulas may vary across brands. Paint a thin coat of the mixed resin on the portions of the fuel tank that will be covered with the cloth and allow it to dry. Drying time will depend on temperature and ventilation. It may take as little as 30 minutes on a warm day outside or several days inside in a cool place.
After the first coat has dried, apply a heavy coat of mixed resin and immediately place the cloth on it, working out any air bubbles and ensuring it lays flat. Then, thoroughly saturate the cloth with more resin. After this second coat has dried, apply additional coats as needed to achieve a smooth finish, allowing the resin to dry between each coat. Ensure that you apply enough coats so that the texture of the cloth is no longer visible.
Finally, once the final coat has completely dried, sand or grind any rough spots and feather the edges where the fibreglass ends. After painting the tank, the fibreglass work will be seamlessly concealed.
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Cut the fibreglass
Cutting fibreglass can be an unpleasant task, so it's important to take the right precautions and use the correct tools. Before you begin, make sure you're working in a clear, spacious area, such as a driveway, garage, or workshop. If you're working inside, ensure there is adequate ventilation by opening a door or window. Cover the table with a sheet of plywood or cardboard to protect its surface.
When cutting fibreglass, it's crucial to prioritise your safety. Wear protective clothing, including long sleeves, gloves, goggles, and a dust mask or respirator. Fibreglass particles can irritate the skin, eyes, and respiratory system, so covering your body and taking measures to avoid inhaling particles is essential.
Now, let's talk about the fibreglass itself. If you're cutting fibreglass cloth, start by pulling out any frayed strands to ensure you have a clean edge to work with. Square up the fabric with the edge of the table to create a straight line, and smooth out any bumps or creases with your hands. If you're working with a fibreglass panel, mark the cutting line with a ruler or straightedge.
For straight cuts, you can use a circular saw or a carbide-tipped blade. If you need to cut curves, a fine-toothed jigsaw or a reciprocating saw with a fine-tooth blade is a better option. Cut slowly and steadily, always staying just inside the line. After each cut, pull out any frayed strands to maintain a clean edge.
Remember to take your time, work carefully, and prioritise your safety throughout the entire process.
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Mix the resin
Mixing resin for a fibreglass fuel tank is a delicate process. Firstly, ensure that the fuel tank is very clean. Using a wire brush on a grinder is an effective method to achieve this. Once the tank is clean, cut the fibreglass to fit the tank. The fibreglass cloth should cover the bottom and up the sides of the tank. This may require cutting the cloth into multiple pieces to ensure complete coverage, especially for irregularly shaped tanks.
Now, you can begin the process of mixing the resin. Follow the mixing directions provided with your chosen resin, as different companies use different formulas. Generally, you should mix enough resin for a thin coat on the tank. For a kerosene fuel tank, an epoxy resin is recommended. One successful combination is the West System 105 resin and 209 extra slow hardener. Another option is to use polyester resin, although some sources advise against this. The curing agent for fuel contact should be an aromatic amine, such as EZ POXY 87 hardener.
Once you have prepared the resin, paint a thin coat of it on the portions of the fuel tank that will be covered with the fibreglass cloth. Allow this first coat to dry, which can take anywhere from half an hour in warm outdoor conditions to several days in a cool indoor environment. After the first coat has dried, apply a heavy coat of mixed resin and immediately place the fibreglass cloth on top, working out any air bubbles and ensuring it lays flat. Completely saturate the cloth with more resin, using your fingers to work the cloth down.
After this second coat has dried, apply as many additional coats of resin as necessary to achieve a smooth finish. Allow the resin to dry between each coat and ensure that you cannot see or feel the texture of the cloth underneath. Once the final coat has dried, you may need to sand or grind off any remaining rough spots. Finally, give the entire tank a coat of paint to complete the process.
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Apply resin and cloth
Yes, it is possible to fiberglass a fuel tank. Here is a detailed, step-by-step guide on how to apply resin and cloth to a fuel tank:
Before applying the resin and cloth, ensure that your work area is well-ventilated as the resin has a strong odour. Start by painting a thin coat of mixed resin on the portions of the fuel tank that will be covered with cloth. Allow this first coat to dry completely. The drying time will vary depending on the temperature and ventilation; it may take as little as 30 minutes outside in warm weather or several days inside a cool place.
Once the first coat is dry, apply a heavy coat of mixed resin. Immediately place the cloth on top, working out any air bubbles and ensuring it lays flat. Use your fingers to smooth out the cloth and get it to adhere to the resin properly. You can use a brush cleaner to remove any resin from your hands.
It is important that the cloth is thoroughly saturated and laying flat. After the cloth is in place, apply another coat of resin to completely saturate the cloth. Allow this second coat to dry.
Inspect the tank and apply additional coats of resin as needed to achieve a smooth finish. Make sure to allow the resin to dry between each coat. Apply enough coats so that you can no longer see or feel the texture of the cloth underneath.
When the final coat has dried, you can sand or grind any rough spots and feather the edges where the fiberglass ends. Finally, give the entire tank a coat of paint, and your fuel tank will be as good as new!
It is important to note that proper preparation is key to a successful fibreglassing project. Make sure the tank is thoroughly cleaned and prepared before beginning the fibreglass application process. Additionally, always follow the safety instructions and recommendations provided by the manufacturers of the resin and cloth products you are using.
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Sand and paint
Sanding and painting a fuel tank is a meticulous process that requires careful preparation and multiple steps. Here is a comprehensive guide to help you achieve a smooth and professional finish:
Preparation:
Before you begin sanding and painting, there are several important preparation steps to ensure a safe and successful outcome:
- Drain the fuel tank: Completely drain any gasoline from the tank and allow it to air out until no fumes remain. Gasoline is highly flammable, so this step is crucial for safety.
- Remove existing paint: If there is any previous paint on the tank, it is essential to remove it for the best results. This can be done through various methods, including sanding, sandblasting, or using chemical paint removers.
- Clean the tank: Ensure the tank is thoroughly cleaned to remove any dirt, grease, or debris. A wire brush attached to a grinder can be effective for this step.
- Inspect and repair: Look for any dents, scratches, or imperfections on the tank. Minor imperfections can be filled with spot putty, while deeper scratches and dents may require more extensive repair.
- Protect surrounding areas: Cover any openings, such as the filler neck, petcock assembly, and fuel gauge mounting areas, with duct tape to prevent paint from getting inside the tank.
Sanding:
Sanding is a critical step in creating a smooth and even surface for the paint to adhere to:
- Choose the right sandpaper grit: The grit of the sandpaper depends on the stage of the process and the desired finish. Start with a lower grit, such as 180-grit, to remove any existing coatings or smooth out imperfections. Then, progress to finer grits, such as 1500-grit or 2000-grit, for a smoother finish.
- Sand with consistent pressure: Apply even and consistent pressure when sanding to achieve a uniform finish. Avoid using your hands to hold the sandpaper, as it can cause uneven pressure and result in tiny dents or waves.
- Use a sanding block for curved areas: When sanding curved surfaces, attach the sandpaper to a sanding block to follow the contours of the tank smoothly.
- Wet sanding: Some processes, especially when working with clear coats, involve wet sanding. Soak the sandpaper in water and then use it to sand the surface, following the appropriate guidelines for your paint system.
Painting:
The painting process involves multiple steps and coats to achieve a durable and aesthetically pleasing finish:
- Primer application: Apply a minimum of five coats of primer, sanding between each coat. This creates a smooth base for the paint and helps the new paint adhere better.
- Base coat application: Use a spray gun to apply at least three to four coats of the base paint colour, allowing each coat to dry before proceeding.
- Clear coat application: After the base coats have dried, apply at least three to four coats of a clear coat polymer. This protective layer adds gloss and safeguards against gasoline drips.
- Buffing and polishing: Once the clear coats have dried, you can optionally buff and polish the paint to achieve a desired level of shine and smoothness.
Please note that it is crucial to follow the specific instructions and recommendations provided by the manufacturers of the paint and associated products you are using. Additionally, always work in a well-ventilated area, and take the necessary precautions to protect yourself from paint fumes and chemicals.
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Frequently asked questions
Yes, you can.
The first step is to get the tank very clean. Using a wire brush on a grinder is an effective way to clean the outside of the tank.
Cut the fiberglass to fit the tank. You can cut the cloth to cover the bottom and up the sides in one piece by making cuts at the corners.
First, paint a thin coat of the mixed resin on the portions of the fuel tank that will be covered with cloth and let it dry. Then, apply a heavy coat of mixed resin and immediately put the cloth on, working out all air bubbles and making sure it lays flat.
After the final coat has dried, sand or grind off any rough spots. Feather the edges where the fiberglass ends and then paint the tank.
