Sylvie Willis
Aluminium fuel tanks are prone to damage over time, and there are several ways to repair them. The most common method is to use an epoxy putty and then cover the tank with a thin layer of fibreglass and epoxy resin. Other methods include using liquid metal sealants, welding, or even replacing the tank with a plastic or polyethylene alternative. It is important to ensure the tank is thoroughly cleaned and dried before repairing, and to be cautious of potential dangers when working with flammable substances.
Characteristics and Values Table for Fixing an Aluminum Fuel Tank
| Characteristics | Values |
|---|---|
| Corrosion | Remove corrosion and use a metal epoxy to repair |
| Moisture | Ensure tank doesn't sit in moisture; use plywood bed, epoxy, and plastic strips |
| Cleaning | Clean metal, etch/alodine wash, prime with epoxy primer, and paint for protection |
| Welding | Welding is possible but may not be worth the cost and effort; consider tank replacement |
| Sealant | Use sealants like JB Weld, Marine-Tex, or Loctite Weld Epoxy to fix small holes and leaks |
| Replacement | Consider tank replacement, especially for older tanks or extensive damage |
| Purging | Purge with nitrogen or argon to displace vapors and oxygen before welding |
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What You'll Learn
Clean the tank and use a metal epoxy to fix corrosion
To fix an aluminium fuel tank, it is important to first clean the tank and then use a metal epoxy to fix any corrosion.
Firstly, to clean the tank, you will need to remove any corrosion and grime. You can use a product like Eagle 1 A to Z Wheel Cleaner, Gumout, Pyroil, Holley, CRC, or similar products to dissolve any varnish and gummy residues. Spray the cleaner into the tank, add a small amount of water, and let it soak before draining and repeating. You can also try using xylene or toluene, covering but not sealing the openings, and letting it sit in the sun so the solvent evaporates and condenses, dissolving the grime. If you are not concerned about the finish, you can use an acid such as aluminum brightener to clean the tank, but be aware that it will turn the aluminium white.
Once the tank is clean, you can address any corrosion. You will need to remove all corrosion down to the good metal. This can be done by grinding and sanding the affected areas. Make sure to wear the appropriate safety gear, including eye protection, during this process.
After the corrosion has been removed, you can apply a metal epoxy to the affected areas. Choose a strong epoxy like JBWeld or Marine-tex Gray, and follow the instructions on the product for proper application. You may need to lay plastic strips on the bottom of the tank and epoxy or polyester a piece of fiberglass over them for added support.
It is important to note that some sources advise against using epoxy on aluminium fuel tanks, as it can cause issues if you decide to weld the tank later. One user reported that their first patch using International Marine Epifill 2:1 epoxy failed, but their second attempt, reinforced with fibreglass tape, lasted eight years. Another user recommended using a Kreem tank liner in addition to epoxy to ensure that any leaks are prevented. Therefore, while epoxy can be a temporary solution, it may be best to consult a professional welder for a more permanent repair.
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Use nitrogen or argon to displace vapours and liquids before welding
Welding on a fuel tank can be extremely dangerous due to the risk of fire and explosion. Even if the tank appears empty, residual fuel vapors can ignite and cause explosions. Before welding, it is crucial to take thorough preparation and precautionary steps to mitigate these risks.
Firstly, ensure the tank is completely drained of all fuel, including residual vapors. Then, flush the tank with water or a non-flammable solvent like isopropyl alcohol or acetone to remove any remaining fuel.
Next, purge the tank with an inert gas such as nitrogen or argon to eliminate any residual fuel vapors and reduce the risk of explosions. This process is known as inert gas purging. Inert gases do not react with other substances, which helps displace any remaining oxygen and fuel vapors, creating a safer environment for welding.
Nitrogen is a suitable choice for inert gas purging, and it is also cost-effective. However, argon has the advantage of being heavier than air. After an initial fast purge to displace oxygen and vapors, a slow purge of argon through a diffuser near the bottom of the tank will remove all remaining oxygen, making the welding process safer.
CO2 can also be used for purging, especially if the opening being welded is at the top of the tank. If the opening is at the bottom, nitrogen is preferred. Using dry ice is an option, as it continually releases CO2 gas, providing a continuous overflow of purge gas that prevents air from entering the tank.
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Welding small pin holes with JB Weld epoxy
Aluminium fuel tanks can be repaired by welding, but this is a complex process that requires expertise. Before welding, the tank must be thoroughly cleaned and purged of any fuel, vapour, and oxygen. This can be done using nitrogen or argon gas, with the latter being heavier than air and thus more effective at displacing oxygen. Additionally, it is crucial to address the root cause of the damage, such as corrosion or electrolysis, to prevent future issues.
For small pin holes, a product like JB Weld can be used as a temporary fix. JB Weld is an epoxy putty that can patch holes and seal leaks in various materials, including aluminium and fuel tanks. It can be used underwater and has a set time of 25 minutes, hardening within an hour. However, it is important to note that some users have found it challenging to work with, especially when filling small holes as it tends to run down unless given time to set.
To use JB Weld effectively for patching small pin holes, follow these steps:
- Clean the area around the pin holes by grinding and sanding to create a smooth surface.
- Remove any dirt, grease, or debris from the surface to ensure a strong bond.
- Knead the required amount of JB Weld putty with your fingers until it reaches a uniform colour.
- Let the putty set for about 30 minutes before applying it to the holes. This will help prevent it from running down.
- Apply the putty to the holes, ensuring it fills them completely.
- Allow the putty to cure for at least 25 minutes.
- After curing, you can drill, tap, file, sand, or paint the repaired area as needed.
While JB Weld can provide a temporary solution for small pin holes, it is not a substitute for welding or professional repair. For larger holes or more extensive damage, welding may be necessary. Additionally, it is important to consider the age and condition of the fuel tank, as older tanks or those with multiple issues may require replacement rather than repair.
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Cover the tank with a thin layer of fibreglass and epoxy resin
When fixing an aluminium fuel tank, it is important to note that the tank should not be exposed to moisture. One way to repair such a tank is to cover it with a thin layer of fibreglass and epoxy resin.
First, ensure that the tank is cleaned thoroughly, removing all loose debris and dirt. Next, use a sanding block or sander to smoothen the surface. It is important to wear safety goggles and a dust mask during this process. Once the surface is prepared, you can apply a thin layer of epoxy resin.
Epoxy resin is a popular choice for repairs as it is strong and durable. When using epoxy resin with fibreglass, consider using a 4 oz cloth and a 2:1 epoxy resin mixture. This will provide strength and flexibility to the repair. Apply the epoxy resin carefully and thoroughly to the tank, ensuring all damaged areas are covered.
After applying the epoxy resin, lay the fibreglass cloth over the resin, pressing it down gently to ensure it adheres well. You can use woven roving, which is a heavy, coarse plain weave cloth that will help build thickness and provide strength. Ensure the fibreglass is smooth and free of wrinkles. Once the fibreglass is in place, apply another thin layer of epoxy resin over it, creating a protective barrier. Allow the resin to dry completely before sanding it smooth.
It is important to note that working with epoxy resin and fibreglass requires caution as the chemicals involved are toxic and flammable. It is recommended that only professionals handle these materials.
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Prevent corrosion by ensuring the tank doesn't sit in moisture
To prevent corrosion, it is important to ensure that your aluminium fuel tank does not sit in moisture. This means avoiding any contact with water, including moisture from the ground or the air.
Firstly, inspect the tank for any signs of corrosion or damage. You can do this through non-destructive testing (NDT) methods, which can pinpoint any damage or anomalies without the need to clean or remove the tank. This is especially important for checking the base plate, which is not visible without NDT. Small amounts of corrosion are inevitable, but it is important to be proactive in addressing it to maintain fuel quality and prevent downtime.
If corrosion is present, you will need to remove it down to good metal. This can be done through grinding and sanding, ensuring that the surrounding metal is in good shape. It is important to keep the area clean and dry during this process to prevent further corrosion.
Once the corrosion is removed, you can apply a protective coating to the affected area. This can include using an epoxy primer, such as a two-part etch/alodine/strontium chromate epoxy primer, which provides excellent protection. You can also paint over the epoxy primer for added protection. Additionally, consider using a corrosion-resistant finish, such as Hammerite Direct to Rust Metal Paint, which repels water and prevents rust formation.
To further prevent moisture-related corrosion, ensure that the tank bed is made of plywood, epoxy-saturated, and glassed over. You can also lay plastic strips on the bottom of the tank and bed them onto the glassed floor using an appropriate adhesive. This creates a barrier between the tank and any potential moisture, allowing air circulation and prolonging the life of the tank.
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Frequently asked questions
It is recommended to use an epoxy putty and then cover the tank with a thin layer of fibreglass and epoxy resin. This should keep the tank functional for another 10 years.
Marine-Tex is recommended as the best epoxy to repair aluminium fuel tanks. It is a tenacious epoxy that can be applied after cleaning the area with sand and acetone.
"JB Weld" will work for small pin holes. Clean the area and scuff sand it for better adhesion. If the holes are all the way through, it is recommended to use Marine-Tex and cloth.
