Mercedes Mullins
Brushed steel fuel tanks are susceptible to rust, which can cause havoc by travelling and creating hazards for carburetors, petcocks, and fuel pumps. Rust is caused by water trapped inside the fuel tank, which can occur due to condensation, refuelling in rainy or snowy weather, or water pooling at the bottom of the tank. To prevent rust, it is important to keep the fuel tank full to avoid exposing the metal to air. If rust does occur, there are several methods to remove it, including using a fuel tank cleaner, distilled white vinegar, or a salt and water solution with a battery charger. Once the rust is removed, the tank can be coated with a sealant or a product like Red-Kote to protect it from future corrosion.
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What You'll Learn
Removing paint with paint stripper and a wire brush
First, it is important to choose the right type of paint stripper or remover for the job. Chemical paint strippers can effectively remove paint from metal surfaces, but they may require multiple applications to reach the bare metal. Apply the paint stripper according to the manufacturer's instructions, being sure to work in a well-ventilated area and wear appropriate protective gear.
Once the paint stripper has been applied, use a paint scraper to remove the bulk of the paint. This process may need to be repeated to remove stubborn layers of paint. It is important to note that this method can be labour-intensive and may not be suitable for large surface areas.
Next, a wire brush can be used to remove the remaining paint and residue. Start with a dry brush and use a sweeping motion to remove any loose or blistered paint. Then, apply a solvent or thinner to the surface and scrub thoroughly with the wire brush. Use more force in areas where the paint is difficult to remove. The wire brush is especially useful for getting into tight spaces and hard-to-reach areas.
After using the wire brush, it is important to clean the brush, especially when dealing with oil-based paint. Rinse the brush with water or use a solvent such as mineral spirits.
Finally, once the paint has been removed, the surface may require additional treatment. Light sanding can be done to smooth out the surface, and a clear coat or primer can be applied to protect the bare metal and prevent rusting.
It is important to note that this process may not always result in a perfect finish, as any imperfections in the metal will be visible. Additionally, the chosen method of paint removal should be considered carefully, as some methods may not be suitable for certain surfaces or may require specialised equipment.
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Using anti-rust treatments
Rusting is a common problem in fuel tanks, especially with today's ethanol-gasoline blends being more corrosive than non-ethanol gasolines. Rust can create pin holes from which fuel can leak, and it can also weaken seam welds, creating a fire hazard. To prevent rust from forming in your brushed steel fuel tank, there are several anti-rust treatments you can use:
KBS Coatings
KBS offers a Fuel Tank Sealer System that can effectively clean, de-rust, and seal your fuel tank. The system includes a RustBlast solution, which is left to soak in the tank for about 45 minutes while rotating the tank every ten minutes to etch all surfaces. After rinsing and drying the tank, the Gold Standard Tank Sealer is applied. This sealer cures into a tough, fuel-impervious coating, sealing small pinholes and weld seams to prevent the return of rust and corrosion.
Fertan, Krust, or Similar Products
These chemical treatments can be used to treat rust inside fuel tanks. However, there may be concerns about their effectiveness if there is residual diesel or paraffin on the metal, or if they will contaminate new diesel.
Diesel
Some forum users suggest that diesel acts as a good preservative of steel. Keeping your tank filled with diesel can help prevent rust, as it reduces the intake of moisture and air, which are contributing factors to rust formation.
Anti-Rust Clear Coat
After stripping and sanding your fuel tank, applying an anti-rust clear coat can help protect the surface from rusting. This method is commonly used by rat rodders.
Regular Cleaning and Maintenance
Emptying and cleaning your fuel tank regularly can help prevent rust. Steam cleaning or pressure washing the inside of the tank can remove diesel sludge and other contaminants that can contribute to rust formation. Additionally, ensuring that your tank is completely dry before refilling can reduce the chances of rust developing.
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Applying sealant to prevent leaks
To prevent leaks in a brushed steel fuel tank, you must first remove any paint from the tank. This can be done using a chemical paint stripper or paint thinner, and a wire brush or a wire wheel. Once the paint has been removed, you can use a rotary wire brush to get rid of any remaining residue.
After the tank is free of paint, you can apply a sealant to prevent leaks. One option is to use a gasket sealant, which is designed to make paper and cork gaskets waterproof. However, it's important to note that gasoline will eventually break down this type of sealant. A more durable solution is to fill the tank with water and then oxy-acetylene weld the hole shut.
If you're looking for a quicker fix, you could try using a screw with a gas-proof sealant or a product like "Seal All" Oil & Gas adhesive. Just be sure to clean the area with alcohol and carb cleaner first to ensure that it's free of oil and gas. Let the Seal All set overnight, then apply a layer of E6000 sealant and let it set again overnight.
Another option is to use a two-part epoxy adhesive, which can be effective for sealing leaks in plastic tanks. For best results, follow the instructions on the product you choose and take the necessary precautions when working with chemicals and sealants.
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Repairing holes with JB Weld
JB Weld is an epoxy repair product that has been used for over 40 years. It is suitable for repairing small pinhole leaks in a metal fuel tank. However, it is not recommended for major damage like gashes, large holes, or significant corrosion.
- Work in a well-ventilated area, preferably outdoors, as fuel leaks can release dangerous fumes. If your tank still has fuel in it, extinguish any nearby flames as gas fumes can travel far.
- Locate the leak. Dry the tank with a towel and watch for the leak. You may need to clean the tank with a brake cleaner to make the leak more obvious. Once found, mark the area with a pencil.
- Put on safety goggles and clean the area around the leak. Ensure you clean at least three inches around the damaged area. Use sandpaper to sand the tank down to the bare metal. This removes any paint, rust, or grime and creates a rough surface for the epoxy to adhere to.
- Prepare the JB Weld epoxy by cutting off an amount sufficient to cover the repair. You will need enough to cover the hole and the surrounding area.
- Knead the epoxy to mix the two colours uniformly until it becomes a dark grey or uniform light grey colour.
- Clean and wipe the repair area dry once more.
- Press the epoxy putty into the centre of the hole and work it flat against the tank, ensuring the hole is sealed. Smooth out the putty so that it is flush with the tank's surface.
- Allow the epoxy to cure. The curing time may vary depending on the product and instructions, but some users have reported curing times of 24 hours.
- After curing, you may choose to paint the tank.
It is important to note that while JB Weld can provide a temporary solution for repairing holes in a fuel tank, it may not be a permanent fix. Some users have reported varying degrees of success, with the repair holding for a few months to over a year. The longevity of the repair depends on the preparation of the surface and how the product is applied. Additionally, consider using additional materials like fiberglass repair cloth for added strength.
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Powder coating
To powder coat a fuel tank, the tank must first be thoroughly cleaned and prepared. This includes draining and hosing out the tank, ensuring all plugs and blockages are removed, and neutralizing any fumes. Some sources recommend using a lit torch inside the tank to eliminate fumes and preheating the tank in an oven before coating. It is also important to consider the type of fuel tank you are working with, as plastic gas tanks, for example, cannot be powder-coated due to melting at oven temperatures.
Once the fuel tank is properly prepared, the powder coating process can begin. The powder coating itself is typically applied in a spray format, using a spray gun or a similar tool. The powder is then cured in an oven, where it melts and forms a hard, durable finish. It is important to note that the oven temperature must be carefully controlled to avoid melting the tank or any internal seals.
Some sources recommend sealing the fuel tank before powder coating, especially if the tank is new and has never been used. This can help prevent rust and protect the tank from deterioration. However, others suggest that powder coating first and then sealing the tank can be effective, as the sealer may not hold up to the high temperatures of the powder coating process.
When choosing a powder coating for your fuel tank, it is important to select a product specifically designed for this purpose. While some standard powder coatings may work, there are also specialized coatings available that are fuel and UV resistant, ensuring a long-lasting and durable finish. It is also recommended to look for a reputable powder coater with experience in coating fuel tanks to ensure the best results.
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Frequently asked questions
Removing rust from a fuel tank is a simple process. First, fill the tank with distilled white vinegar and leave it to sit for at least one night. The acetic acid in the vinegar will dissolve the rust. Next, rinse the tank with water and ensure it is completely dry. Finally, coat the inside of the tank with a sealant product like Red-Kote to prevent future rusting.
There are several products available for sealing a brushed steel fuel tank. KBS Coatings offers a variety of tank sealer kits for different-sized fuel tanks, which include the necessary materials for cleaning, rust removal, and sealing. Northern Factory's Gas Tank Cleaner is another product that can be used to eliminate contaminants and dirt from the tank.
If you notice any rust spots or flaking inside your fuel tank, it is important to address the issue promptly. Rust in fuel tanks can cause drivability problems and lead to costly repairs if left untreated. Additionally, if you observe any pinholes or spots where the rust has made the tank wall too thin, it may be necessary to cut out the damaged parts and weld new metal patches.
