Ameer Randolph
Rust in an ATV fuel tank can be a major concern, potentially rendering your vehicle useless and leading to costly repairs. While some suggest replacing the tank, there are several methods to remove rust before it causes extensive damage. These include using abrasive materials, chemicals, electrolysis, or chemical resealing treatments. For example, one method involves filling the tank with nuts, bolts, or chains and shaking vigorously, while another uses a mild acid like vinegar to dissolve the rust. With the right tools and precautions, you can effectively tackle rust in your ATV fuel tank and prevent further issues.
Removing Rust from an ATV Fuel Tank
| Characteristics | Values |
|---|---|
| When to remove rust | If the gas tank has holes or damage from rust, it is better to replace it. However, if the structural integrity of the tank is uncompromised, rust can be removed. |
| Rust removal methods | Abrasive materials, electrolysis, chemical treatments, acids, or shaking with abrasive materials inside |
| Abrasive materials | Nuts, bolts, wood screws, sheet metal screws, chains, light chain, steel shot, BBs, clean round stones, sand |
| Chemicals and acids | Evaporust, acetone, rubbing alcohol, parts cleaner, muriatic acid, phosphoric acid, vinegar, baking soda, salt, kerosene, diesel, gasoline, soapy water |
| Other tools | Flashlight, mirror, cell phone, bore scope, pressure washer, garden hose, degreaser, respirator, fire extinguisher, gloves, eye protection, filtration mask, inline fuel filter |
| Post-cleaning | Seal the tank, install a fuel filter, replace the fuel line, clean the spark plug, prime the carb, check for fuel leaks |
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What You'll Learn
Using a chemical treatment, such as acid, acetone, or vinegar
If your ATV fuel tank has rust, it is best to address it as soon as possible to prevent the rust from corroding the tank and creating holes, which could lead to fuel leaks and increase the risk of fire. While there are various methods to remove rust from a fuel tank, using a chemical treatment such as acid, acetone, or vinegar is an effective approach. Here is a detailed guide on how to do it:
Preparation
Before starting the rust removal process, it is crucial to take necessary safety precautions. Put on gloves, a cartridge-type charcoal respirator, and other appropriate personal protective equipment (PPE). Have baking soda, warm water, and a blow dryer or air compressor/heat gun ready for later steps.
Using Acid
Muriatic acid, which is hydrochloric acid (HCl), can effectively remove rust from your ATV fuel tank. However, it is essential to know that muriatic acid can initiate further rusting due to the presence of chloride. Therefore, it is recommended to use phosphoric acid (H3PO4) or nitric acid (HNO3) instead, as they are chloride-free and safer for metal.
Seal all openings of the fuel tank except for the fuel fill. Pour in enough acid to slosh around and then vigorously move the tank by tipping and rolling it. Check the progress through the filler, and if needed, add more acid.
Neutralizing and Cleaning
Once you are satisfied with the level of derusting, neutralize the acid by pouring baking soda into the tank. Then, flush the tank with warm water to remove any remaining acid and rust particles.
Preventing Flash Rust
After neutralizing and cleaning, the metal will be prone to flash rusting. To prevent this, you can apply a product like Red-Kote, which is specifically designed to protect metal from corrosion. Alternatively, you can use a fog or mist of WD-40 to temporarily prevent flash rusting.
Using Acetone
Acetone is a powerful solvent that can be used to remove any remaining residue or excess moisture from the metal after the acid treatment. However, acetone is aggressive and can damage certain materials, such as petcock pipes and paintwork. Use acetone with caution and ensure proper ventilation during its application.
Using Vinegar
White vinegar is another chemical treatment option for rust removal. Fill your fuel tank with vinegar and a bunch of clean round stones, bolts, or nuts. Seal the tank and shake it vigorously for about 10 minutes. Repeat this process several times, emptying and rinsing the tank between treatments. This method may not restore the tank to bare metal, but it effectively removes rust.
Remember, always work with these chemicals in a well-ventilated area and follow safety guidelines to protect yourself and the surrounding surfaces.
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Removing the tank and using electrolysis
If your ATV fuel tank is rusty, it could render your vehicle useless and lead to an expensive trip to the auto repair shop. It is important to address the issue before the rust causes further damage to the tank, such as holes that could lead to fuel leaks. Depending on the severity of the rust, you may need to replace the tank entirely. However, if the rust is caught early, you may be able to remove it using electrolysis.
To begin the process of removing rust from your ATV fuel tank using electrolysis, you will first need to remove the tank from your ATV. This typically involves draining the fuel tank, removing the fuel lines, and dropping the suspension if your ATV has one. Once the tank is removed, you can begin the electrolysis process.
Electrolysis involves using an electric current in an electrolytic bath to remove rust from metal surfaces. It is a cheap and effective method that can remove rust without damaging the metal. To perform electrolysis, you will need a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate. You may also need clamps, a piece of steel round bar as a sacrificial anode, and a plastic spray paint can lid to keep the anode in position without touching the metal of the tank.
Once you have gathered your materials, fill the metallic container with sodium carbonate and hot water. The ratio is about one cup of sodium carbonate for each five-gallon bucket of hot water. Submerge the fuel tank in the solution and allow it to sit for at least 24 hours. The amount of time needed will depend on the amount of rust in the tank.
After the electrolysis process is complete, rinse the tank thoroughly with water to remove any remaining residue. You may need to repeat the electrolysis process multiple times to fully remove all the rust from the tank. In between sessions, you can extract the anode, clean off the accumulated rust, and sand it down to remove any stubborn bits.
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Draining the tank and using abrasive materials, such as nuts and bolts
If you have rust in your ATV fuel tank, the first step is to drain the gasoline from the tank and allow any residues to drain. You can then examine the inside of the tank with a thin flashlight to understand the extent of the corrosion. This will help you determine where the fluids should be in contact with the rust for longer. Remember that the places with the most corrosion will need to be worked on the most.
Once you have assessed the level of corrosion, you can decide whether to replace the tank or attempt to treat it. If the tank is too damaged, de-rusting alone might not be enough to fix it. If you decide to treat the tank, you can use abrasive materials such as nuts and bolts to remove the rust. These are durable, inexpensive, and effective at scraping away loose rust.
Before adding abrasive materials, you should ensure that your chosen mechanical abrasive is somewhat inert in your chosen acid. You can then add your sheet metal screws, hardware, or BBs. It is important to use common sense when choosing the size of the abrasive materials. While enormous bolts are likely to dent a tank, smaller ones are better, to a point. You want to add just a handful or two to knock off the rust and fling your acid about the tank into nooks and crannies.
If you are using nuts and bolts, it is important to remember that you are not trying to fill the tank with them. You just need enough to knock off the rust. You can also use a length of chain, which has the added benefit of not having to worry about counting the number of rust looseners.
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Sealing the tank with a coating, such as spray-on truck bed coating
Sealing your ATV fuel tank with a coating, such as a spray-on truck bed coating, can be an effective way to prevent and treat rust. Truck bed coatings are protective layers that shield the beds of pickup trucks from external damage caused by long-term use, such as corrosion, fading, and scratching.
Before applying the coating to your ATV fuel tank, it is important to prepare the surface properly. Start by removing any plastic liner in the tank, if applicable. Next, sand the metal surface of the tank with a scuff pad or sandpaper to create a rough surface for better adhesion. Wipe away the sanding dust with a clean cloth. Mask off the surrounding areas with a liner and tape to prevent paint splatter.
When choosing a truck bed coating, opt for a product that is specifically designed for fuel tank applications and offers a lifetime guarantee against rust. Polyurea and polyurethane coatings are suitable options as they provide proper adhesion to various metals. Follow the supplier's instructions for the application process, as it may vary depending on the brand or type of coating.
After applying the coating, allow sufficient time for it to dry and cure completely. Refer to the manufacturer's instructions for the recommended drying time. Once the coating is fully cured, you can reassemble the fuel tank and continue using your ATV.
Additionally, consider using a fuel stabilizer and additive, such as Diesel Formula STA-BIL® Fuel Stabilizer & Additive, to further protect the fuel tank from rust and corrosion. This product can be used in conjunction with the coating to provide a more comprehensive solution.
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Replacing the tank with a new one
If your ATV fuel tank is severely rusted, it may be best to replace it entirely. While there are methods to remove rust from a fuel tank, such as using abrasive materials, chemicals, electrolysis, or chemical resealing treatments, it can be challenging to access the entire inside of the tank. Therefore, if your fuel tank is heavily rusted or has holes, it is recommended to replace it.
- Drain the old fuel tank: Start by loosening the small stop valve of the fuel tank to drain the remaining fuel. If there is no valve, you can remove one of the fuel lines to drain the fuel.
- Remove the fuel lines: There are typically two fuel lines, one attached to the engine and another at the top of the tank. Removing these lines will reduce the pressure of the fuel in the tank.
- Disconnect the fuel pump: If your ATV has a fuel pump, disconnect it from the fuel lines and the tank.
- Remove the old fuel tank: This may involve dropping the suspension, depending on the ATV model. Carefully lift and remove the old fuel tank.
- Inspect the surrounding components: Before installing the new tank, inspect the fuel lines, petcock, and other nearby parts for any signs of damage or corrosion. Replace any damaged components as necessary.
- Prepare the new fuel tank: Ensure that the new fuel tank is clean and free of any debris. If the new tank has a fuel filter, ensure it is installed correctly, following the arrow indicating the fuel flow direction.
- Install the new fuel tank: Place the new fuel tank in the same position as the old one, securing it firmly in place. Reconnect the fuel lines and the fuel pump if your ATV has one.
- Test the fuel system: Once the new tank is installed, check for any leaks or issues. Ensure that the fuel flows smoothly and is under the appropriate pressure. Start the ATV and observe if the fuel gauge readings are accurate.
By following these steps, you can ensure a safe and effective replacement of your ATV's fuel tank. It is important to refer to your ATV's service manual or seek professional assistance if you are unsure about any part of the process.
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Frequently asked questions
Some methods to remove rust from an ATV fuel tank include using abrasive materials, electrolysis, chemical treatments, or chemical resealing treatments.
Some chemical treatments that can be used to remove rust from an ATV fuel tank include muriatic acid, phosphoric acid, vinegar, and baking soda.
Electrolysis involves using an electric current in an electrolytic bath to remove rust from metal surfaces. To perform electrolysis on an ATV fuel tank, you will need a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate.
Yes, an alternative method is to fill the fuel tank with nuts, bolts, or chains and shake vigorously. This method can be used in conjunction with solvents such as acetone, rubbing alcohol, or parts cleaner.
