Rajan Wilcox
Fuel tank pinhole repairs can be tricky, especially if you want to avoid welding. Some methods involve using products like JB Weld, Waterweld, or epoxy to seal the holes, but these may not hold up against gasoline long-term. Other options include brazing or silver soldering, but these require draining the tank and dealing with fumes. For a quick fix, you might try using a product like Seal-All or Red Kote, which can patch fuel tank leaks without mixing and can be found at hardware stores.
Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Fuel tank material | Metal, Aluminum |
| Hole type | Pin holes, hairline cracks, seam pinholes |
| Repair methods | Brazing, soldering, welding, patching, coating, sealing, epoxy filling, screwing, hammering |
| Specific products | JB Weld, Waterweld, Kreem Tank Liner, Seal-All, Red Kote, Caswell's, Evapo-Rust, Oxalic Acid, Phosphoric Acid, Fevi Quick, PSR |
| Preparation | Remove paint, clean and score surface, sand, drain tank, dry tank |
| Tools | Emery cloth, large iron, acetone, ball peen hammer, body putty/resin, gas tank sealer, wire screen, epoxy, green sleeve retainer locktite |
| Safety | Ventilate area, avoid fumes |
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What You'll Learn
Using JB Weld
JB Weld is an effective way to fix pin holes in a fuel tank, but it is not a permanent solution. The epoxy clay can fill small holes and withstand pressure and high temperatures. However, it will not stand up to ethanol or gasoline over time.
First, ensure you are working in a well-ventilated area as fuel leaks can give off dangerous fumes. Put on safety goggles and clean the area around the leak. You should clean at least three inches around the hole, using sandpaper to cover the entire area. Sand down to the bare metal, removing any paint, rust or road grime. A rough surface works better than smooth metal, as the epoxy will have something to grip onto. Do not use power tools as sparks could ignite fumes.
Next, if the tank is not actively leaking, put a small self-tapping screw into the pinhole. Cover the area with a generous amount of JB Weld epoxy putty. Mould it flat against the tank, ensuring the hole is sealed and the putty is smooth. You do not want a large glob on the tank. The putty should harden in five minutes and fully cure in an hour.
If the tank is actively leaking, use the Tank Weld product from JB Weld. This is a mouldable stick that can be shaped into a cone and pushed into the hole to stop the leak. Then, clean the area and cover with the standard JB Weld epoxy.
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Brazing
To braze a fuel tank and fix pinholes, you will need the appropriate brazing equipment, including a brazing torch, filler metal rods, and safety gear such as gloves and eye protection. Ensure you are working in a well-ventilated area to manage fumes, and consider using a candle on a broomstick to manage fumes as well.
Before beginning the brazing process, thoroughly clean the fuel tank to remove any paint, grease, or debris from the surface. This step is crucial for ensuring a strong bond between the filler metal and the base metal of the fuel tank. You may also need to sand or score the surface to create a rough texture that will enhance the adhesion of the brazing material.
Once the fuel tank is prepared, follow these steps:
- Set up your brazing torch according to the manufacturer's instructions, ensuring a steady and controlled flame.
- Choose a suitable filler metal rod that is compatible with the base metal of your fuel tank. For aluminium fuel tanks, consider using aluminium brazing/welding rods.
- Heat the fuel tank around the pinhole area with the brazing torch. Apply heat evenly and avoid overheating to avoid damage or distortion.
- Feed the filler metal rod into the heated area, allowing it to melt and flow into the pinhole. Use the brazing torch to direct the molten filler metal and ensure it fills the hole completely.
- Allow the brazed joint to cool slowly. You can control the cooling rate by directing the flame away from the joint and allowing it to cool gradually.
- Once cooled, inspect the brazed area to ensure the pinhole has been completely filled and sealed.
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Soldering
To fix pinhole-sized leaks in a fuel tank by soldering, you will need to clean the tank, solder the hole, and then seal the tank.
First, clean the tank. If there is paint on the tank, you may need to strip it. If there is rust around the hole, grind or sand it away. Then, clean the area around the hole with sandpaper and a cleaning agent. Some recommend muriatic acid, but this is quite caustic, so be sure to follow the instructions. Others suggest boiling water and dishwasher soap, or a solvent.
Next, solder the hole. If the hole is very small, you can simply melt solder into the hole until it is filled. If the hole is larger, you may need to fill it with something first. One source recommends a large-headed tack. Another suggests a small screw. Then, use a soldering iron or a blowtorch to melt solder over the hole. If you are using a blowtorch, you may need to fill the tank with water first for safety. If you are using a soldering iron, a tinner's iron or a large copper iron is recommended. You will also need flux. One source recommends an acid core 50/50 solder.
Finally, seal the tank. There are many different products available for sealing fuel tanks. One source recommends Kreem fuel tank liner kit. Another suggests a product called Knead-It. A third recommends a two-part tank sealer.
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Seal-All
To use Seal-All to fix pinhole leaks in a fuel tank, start by cleaning the area around the hole. Then, apply the Seal-All around the hole. It works better if it is applied to a flat surface, as it will spread out and smooth itself. Once it is dry, it will last a long time—it will hold for years.
One user reported that they applied Seal-All around the hole and then put a piece of screen wire over the hole before covering it with more Seal-All. They reported that this method worked well and lasted a long time.
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Epoxy
There are epoxy products specifically designed for patching fuel tanks, which can be found in auto supply stores. These products are formulated to withstand fuel types such as gasoline and diesel. When using epoxy, it is important to ensure that the tank is empty or that the leaking fuel is contained to allow the epoxy to cure properly.
One technique for repairing pinhole leaks is to use a short lag bolt with a washer and a rubber washer/grommet against the tank. The bolt is screwed into the hole, and the area is then sanded to clean the tank surface. The epoxy compound is then applied over the bolt, providing a durable repair.
Another method involves using a ball peen hammer to hammer the pinhole area inward, filling it with body putty or resin, and then sanding it flush with the tank. Gas tank sealer can also be applied to the inside of the tank for added protection.
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Frequently asked questions
You can use products such as Seal-All, JB Weld, Waterweld, or Fevi Quick to fix pin holes in a fuel tank without welding. However, it is important to ensure that the area is thoroughly cleaned and dried before applying any of these products.
Brazing is a type of welding that uses a filler metal, such as silver solder, to join two pieces of metal together. To braze a fuel tank, you will need to drain the tank and ensure it is completely dry before beginning the process.
You can use soft solder or silver solder to fix pin holes in a fuel tank. It is important to use a large copper soldering iron and to ensure that the area is well-ventilated to avoid inhaling any fumes.
If the pin holes in your fuel tank are due to rust, it is likely beyond repair and will need to be replaced. Additionally, if you have tried multiple methods to fix the pin holes without success, it may be time to consider purchasing a new fuel tank.
Yes, there are fuel tank sealers available that can help to fix pin holes. Some options include Red Kote, Caswell's, Kreem Tank Liner, and Gas & Oil sealer. These products are designed to seal the tank and prevent leaks.
