Katerina Swanson
Rust in a fuel tank can be a serious issue, potentially causing costly repairs and even rendering your vehicle useless. If you smell gas or spot leaks, this could indicate corrosion has penetrated and created holes in the tank. Luckily, there are ways to get rid of rust before it damages the tank, including using abrasive materials, chemicals, electrolysis, or chemical resealing treatments. If the tank is too damaged, however, it may be necessary to replace it. This guide will outline some methods for removing rust and restoring a fuel tank to its former glory.
Characteristics and Values Table for Fixing a Rusted Fuel Tank
| Characteristics | Values |
|---|---|
| Safety | Gas vapors are hazardous and can irritate your lungs and enter the bloodstream, killing tissues in your body. Driving a vehicle with a damaged fuel tank is a safety hazard and can cause fuel leaks, affect fuel gauge readings, and leave you stranded. |
| Prevention | Frequently ridden motorcycles are not as susceptible to tank rust. Keeping the tank full of gas can also prevent rust from returning. |
| Inspection | Assess the extent of the rust. Look for pinholes or spots where the rust has made the tank wall too thin. |
| Removal Techniques | Electrolysis, abrasive materials, chemicals, or chemical resealing treatments. For surface rust, use a chain or nuts and bolts, then rinse and blow-dry. |
| Cleaning Products | KBS Coatings Gold Standard Tank Sealer kit, Red-Kote, Kreem Coat, Super Washing Soda, Acetone, Naptha |
| Replacement | If the tank has extensive holes or damage, it is better to replace it. Consider the cost of replacement parts and repainting. |
| Refinishing | Consider replacing the fuel pump if exposed to rust particles. |
| Post-Treatment | Reinstall the tank and any removed parts. |
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Remove the fuel tank
Removing the fuel tank is an important step in fixing a rusted fuel tank. Here is a detailed, step-by-step guide on how to remove the fuel tank:
First, turn off the tank fuel petcock. The petcock valve controls the flow of fuel, and turning it off will prevent any fuel leakage during the removal process. Next, locate the fuel tank and identify the connections and fittings that secure it in place. This may vary depending on the vehicle, but typically, the fuel tank is fastened with bolts or clamps.
Once you have identified the connections, proceed to disconnect the fuel lines and electrical connections attached to the fuel tank. This may include detaching fuel hoses, vent hoses, and wiring harnesses. It is important to label or mark these connections to ensure proper reassembly during installation. Place a container below the tank to catch any residual fuel that may spill during the removal process.
Now, carefully lift or slide the fuel tank out of its housing. Depending on the vehicle's design, you may need to remove surrounding components or support structures to access the fuel tank fully. Take note of any mounting brackets or straps that secure the fuel tank in place and detach them as necessary.
After successfully removing the fuel tank, inspect it for signs of rust and corrosion. This includes checking for pinholes, rust flakes, or weakened areas on the tank's surface. It is crucial to assess the extent of the rust damage to determine the appropriate repair or restoration method. Remember to wear appropriate personal protective equipment, such as gloves and eye protection, when handling the fuel tank to safeguard against any residual fuel or rust particles.
By following these steps, you can effectively remove the fuel tank from your vehicle, allowing you to proceed with the necessary rust removal and treatment processes to restore the tank to its optimal condition.
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Drain the tank
If you have a rusty fuel tank, the first step is to drain the tank. This is a necessary safety precaution as it prevents fuel leaks and spillage when working on the tank. It also allows for a thorough inspection of the tank's interior to assess the extent of the rust.
To drain the tank, start by turning off the tank's fuel petcock if it has one. If not, you can loosen the small stop valve of the fuel tank to allow the fuel to drain out. If there is no valve present, you will need to remove one of the fuel lines to drain the fuel. It is important to have a container ready to collect the drained fuel. One approach is to use a small trash can covered with an old t-shirt or cloth to filter the fuel and capture any particles. Alternatively, you can use a funnel with a coffee filter to ensure that the drained fuel and particles are captured effectively.
Once the fuel is drained, you may find, as in one example, that there is some residual varnish left at the bottom of the tank. This can be drained and rinsed out with water, and the tank can be left to dry. It is important to ensure that the tank is thoroughly dried to prevent the rust from continuing to develop.
In some cases, you may need to remove the fuel lines and the tank itself to gain better access and complete the draining process. This is especially true if you plan to use more intensive methods to remove rust, such as electrolysis or chemical treatments.
Draining the tank is a crucial first step in repairing or restoring a rusty fuel tank. It ensures that the work area is safe and that the extent of the rust damage can be accurately assessed before proceeding with further repair or restoration methods.
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Clean the tank
If the rust in your fuel tank is severe, it may be best to replace the tank. However, if the rust is minor, there are several methods you can use to clean the tank.
First, drain the tank and remove it from the vehicle. If there is a small stop valve, loosen it to drain the fuel. If there is no valve, remove one of the fuel lines. You may need to remove the fuel lines anyway, so check that all fuel has been drained from the tank.
One method to clean the tank is to use a three-part clean/seal/coat kit, such as the KBS Coatings Gold Standard Tank Sealer kit. This involves washing the tank with a cleaner/degreaser solution mixed with water at a 1:1 ratio, then pouring it out and rinsing with water. Repeat this process until the rinse water is clear.
Another method is to use a rubber hose and submerge it in an electrolytic bath to remove the rust. This method involves using an electric current to clean the rust from the metal. To perform electrolysis, you will need a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate. Fill the metallic container with sodium carbonate and submerge the gas tank.
You can also try using a chain or some nuts and bolts, along with a little water, and shaking the tank to remove the rust. Rinse the tank several times, then blow out the inside with a hairdryer or heat gun. With the first gas in the tank, add a bottle of fuel line antifreeze to ensure all moisture is removed.
Once the tank is clean and dry, you can coat the inside with a product like Red-Kote to prevent rust from returning.
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Coat the tank
If the gas tank has holes or damage from the rust, it is recommended to replace it. However, if the rust is only minor, you can try to coat the tank to fix it.
Firstly, drain the old fuel tank and remove the fuel lines. Then, remove the tank by dropping the suspension. Next, you need to ensure that the tank is rust-free and dry. You can do this by using a product like Naptha, rinsing the tank with water, and then drying it in the sun. You can also use a hair dryer or heat gun to ensure the tank is completely dry.
Once the tank is dry, you can coat the inside with a product designed for this purpose, such as Red-Kote or Kreem Coat. Plug any holes with rubber plugs, corks, or masking tape, and then pour in enough of the coating product to cover the entire tank. Reinstall the gas cap and rotate the tank to ensure even coverage. Most tanks will require about half a quart of coating.
After coating, remove the plug from the petcock area and set the tank on a stand above the can of coating, so that any excess product can funnel back into the container for later use.
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Reinstall the tank
Once you have treated your fuel tank for rust, you can reinstall it.
First, ensure that the tank is completely dry and rust-free. If you have had to weld new metal patches, you will need to repaint the tank. You can then coat the inside of the tank with a product such as Red-Kote. Place the tank on a stand that allows the can of Red-Kote to sit underneath where the petcock was removed. Plug any holes with rubber plugs, corks, or masking tape. Pour enough Red-Kote to coat the entire tank, reinstall the gas cap and rotate the tank to ensure even coverage. Most tanks require about half a quart of Red-Kote, but you can use a little more as you will drain the excess. Remove the plug from where the petcock would mount and set the tank on the stand above the can of Red-Kote.
After the tank has dried, replace any parts that were removed and reinstall the tank back on the motorcycle. This is a long-term solution that will prevent rust from returning for many years.
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Frequently asked questions
If you smell gas inside your vehicle or spot gas leaks when you inspect it, your gas tank might have rust. The gas vapors are extremely hazardous to your health and could damage your vehicle.
There are several methods to fix a rusty fuel tank. One method is to use a chemical treatment, such as the KBS Coatings Gold Standard Tank Sealer kit, which retails for $69.95. Another method is to use electrolysis or electrolytic cleaning, which involves using an electric current in an electrolytic bath to remove rust. If the rust is only minor, you could try finding a local radiator shop that will boil the tank out.
If your fuel tank has holes or extensive damage from the rust, it is better to replace it instead of trying to remove the rust. Replacement gas tanks are not very expensive for most vehicles, so it is recommended to replace the tank if it is loaded with rust.
