Regan Brown
Painting a plastic fuel tank can be a challenging task due to the unique properties of plastic and the presence of fuel vapors that can cause bubbling and peeling. However, with the right preparation and techniques, it is possible to achieve a successful paint job on a Polaris plastic fuel tank. One crucial step is thoroughly cleaning and degreasing the tank to remove any dirt, grease, or old fuel residue. This can be done using soap and water, acetone, or a degreaser. After cleaning, the tank should be dried completely before proceeding with any paint application. Some sources recommend roughing up the surface of the tank with sandpaper or screws in a dryer to create a furry texture, which can enhance paint adhesion. It is also important to consider the type of paint and primer used, with some recommending a high-quality primer and an adhesion promoter for better results. Additionally, the use of Rit Dye has been suggested as an alternative to traditional paint, offering a unique coloring option for plastic fuel tanks.
Characteristics and Values Table for Painting a Polaris Plastic Fuel Tank
| Characteristics | Values |
|---|---|
| Cleaning the tank | Use a sponge, water, and soap. Alternatively, use a mix of dish soap and comet. |
| Removing residue | Use a degreaser to remove sticky residue. |
| Sanding | Use sandpaper with grits ranging from 60 to 80, then move to finer grits like 100, 120, and finally 220. Aim for a furry texture. |
| Priming | Prime the spots where the plastic of the tank is visible with a plastic primer. |
| Filler | Apply a 2-pack filler and let it dry thoroughly. |
| Sanding after filler | Sand with P500/600 dry or wet P1000. |
| Painting | Apply the desired colour coat. |
| Clear coat | Finish with a 2-pack clear coat. |
| Alternative methods | Rit Dye can be used to colour the tank. Boil water, add Rit Dye, submerge the tank, and cover the bucket. Alternatively, use a heat gun to heat the sanded tank gently. |
| Preventing bubbling | Empty the tank and let it dry between rides to prevent fuel vapours from causing bubbling. |
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What You'll Learn
Prepping the plastic fuel tank
Painting a plastic fuel tank can be a tricky process due to the potential for fuel vapours to permeate the paint and cause bubbling. However, with careful preparation, it is possible to achieve a lasting paint job. Here is a step-by-step guide to prepping a plastic fuel tank for painting:
Cleaning and Drying the Tank
Begin by thoroughly cleaning the tank to remove any dirt, grease, or old fuel residue. This can be done using a mixture of dish soap and water, or a stronger solvent such as acetone. Ensure that you clean both the inside and outside of the tank, and allow ample time for the tank to dry completely before proceeding.
Sanding and Roughening the Surface
Once the tank is clean and dry, it's time to sand the surface to create a "furry" texture that will promote paint adhesion. Start with a coarse grit sandpaper, such as 80-grit, and sand the entire surface by hand, as electric sanders can be too aggressive and melt the plastic. Progress through the grits, moving to finer grades like 100, 120, and finally 220. This process will help achieve a uniform surface ready for painting.
Priming and Filling
After sanding, use a plastic primer to prime the spots where the plastic of the tank is visible. This will help the paint adhere better and create a more durable finish. Once primed, apply a filler to smooth out any imperfections. A two-pack filler is recommended, and it should be allowed to dry thoroughly before proceeding.
Final Sanding and Prep
Before painting, it is essential to sand the filler with a finer grit sandpaper, such as P500/600 dry or wet P1000. This will create an even surface for the paint to adhere to. It is also crucial to degrease the tank again at this stage to remove any remaining contaminants. Additionally, if there are decals on the tank, they should be removed or covered with tape to protect them during the painting process.
Optional: Sealing and Coating
If desired, an additional step is to seal the inside of the tank to prevent fuel vapour permeation and bubbling. Some options for this include using an Epoxy liner or fibreglass resin. However, it is important to note that sealing the inside of a plastic tank is not always necessary, and some professionals advise against it.
By following these steps, you will have a well-prepped plastic fuel tank that is ready for painting. Remember, the key to a successful paint job is taking the time to properly prepare the surface and ensuring that the tank is thoroughly clean and dry before proceeding.
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$36
Choosing the right paint
Painting a plastic fuel tank can be a tricky task, especially with the risk of bubbling due to fuel vapours permeating through the walls of the tank. The right paint and preparation are key to achieving a long-lasting paint job.
Firstly, it is important to note that regular paint may not adhere well to plastic. Therefore, it is recommended to use a paint designed specifically for plastic, such as Krylon Fusion or a 2K paint. These paints are formulated to bond with plastic surfaces and can handle the unique challenges of painting a plastic fuel tank.
Before painting, the tank must be thoroughly cleaned and prepared. This includes removing any stickers, decals, and components that you do not want to paint. Use a mixture of soap and water or acetone to clean the tank, ensuring all traces of fuel, grease, and dirt are removed. Once clean, the tank should be dried completely, and any remaining residue can be removed with a degreaser.
The next step is crucial to ensuring the paint adheres properly. The surface of the tank should be roughened using sandpaper to create a "furry" texture. Start with a lower grit sandpaper, such as 60 or 80 grit, and gradually increase the grit to 100, then 120, and finally 220. This process will create a textured surface for the paint to grip onto.
After sanding, it is essential to use a plastic primer designed specifically for use on plastic surfaces. This will help the paint adhere better and create a more durable finish. Once the primer is dry, you can begin applying your chosen paint colour, following the manufacturer's instructions for the best results.
In addition to using the right paint and preparation techniques, some people also recommend using a liner or sealant inside the tank to prevent fuel vapour permeation and reduce the risk of bubbling. However, this is a controversial topic, and some sources advise against coating the inside of a plastic tank. Ultimately, the decision to use a liner or sealant is up to the individual, but it is important to research and choose a product specifically designed for this purpose if you decide to go that route.
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Sanding and priming
Sanding:
Before starting, ensure the fuel tank is empty and well-ventilated to allow any fumes to dissipate. Begin the sanding process by using a coarse grit sandpaper, such as 60 or 80 grit cloth-backed sandpaper. It is important to sand by hand, as electric sanders can be too aggressive and melt the plastic. The goal is to create a "furry" or "fur" texture on the surface of the tank. Continue sanding with progressively finer grits, moving to 100, then 120, and finally stopping at 220 grit. This multi-step sanding process will help create a smooth base for the paint to adhere to.
Priming:
Once the tank is sufficiently sanded, it's time to apply a primer. Choose a high-quality primer designed specifically for plastic surfaces, such as SEM Flexible Primer or an adhesion promoter. Follow the manufacturer's instructions for proper application. After priming, it is essential to allow the primer to dry completely before proceeding to the next step.
Additional Sanding:
After priming, it is common to sand the surface again to create an even smoother base for the paint. Use a finer grit sandpaper, such as 320 or 500 grit, to lightly sand the primed surface. This step helps to remove any minor imperfections and creates a uniform finish.
By following these steps of sanding and priming, you will create a strong foundation for the paint to adhere to, resulting in a high-quality and long-lasting paint job on your Polaris plastic fuel tank.
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Painting and drying
Painting a plastic fuel tank is a tricky endeavour due to the possibility of paint bubbling as a result of fuel vapours permeating through the plastic. However, it is not impossible. Here is a step-by-step guide to painting and drying a plastic fuel tank, specifically a Polaris plastic fuel tank.
Firstly, empty the tank and let it dry. Next, remove the fuel cap and the fuel pump (if you wish to). If you would rather not remove the fuel pump, you can mask it with tape. Then, thoroughly degrease the paint. Dirt, grease, and polish will be deep in the scratches, so take your time with this step. You can use a degreaser to soften any sticky residue and then rub it off with your thumb.
Now, you can begin sanding the tank. It is important to sand the tank to create a "'fur'" texture, which will help the paint adhere better. Start with a 60 or 80 grit cloth-backed quality sandpaper and then move to the next grit, such as 100, then 120, and stop at 220. You can use a small squeegee to maintain the curvy shape of the tank and ensure the sandpaper follows the surface correctly. For difficult-to-reach spots, you can use Scotch Brite (grey).
Once you have finished sanding, you can start preparing for painting. Remove any stickers or components you do not want to colour. If there is a clear coat on the tank, it must be sanded off gently before removing the decals. You can use a hairdryer to warm the decals and help remove them more easily. If there is any sticky residue left, you can use a degreaser and then rub it off.
Now, you are ready to start painting. Prime the spots where you can see the plastic of the tank with a plastic primer. Then, apply a filler, preferably a 2-pack filler. Let it dry thoroughly. After it has dried, sand it with P500/600 dry or wet P1000.
Finally, you can start applying the colours of your choice. Once you have finished painting, apply a 2-pack clear coat to protect the paint job. It is important to let the paint dry completely before using the fuel tank again.
Some people have also had success using Rit Dye to colour their plastic fuel tanks. This process involves cleaning the tank, removing the fuel cap, boiling water, and mixing the Rit Dye with the boiled water. The tank is then submerged in the dye mixture and left to soak. However, this method may not be as durable as traditional painting.
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Sealing and finishing
Cleaning and Preparation
Start by emptying the fuel tank and removing the fuel cap and pump. Thoroughly clean the inside and outside of the tank with acetone, dish soap, or alcohol, ensuring all traces of old fuel, grease, and dirt are removed. Let the tank dry completely. Next, sand the tank with grit sandpaper, starting with a coarser grade (around 60 to 80 grit) and working your way up to a finer grade (up to 220 or 320 grit). This process creates a “furry" texture, which will help the paint adhere better. Use a small squeegee to maintain the curvy shape of the tank and ensure the sandpaper follows the surface correctly. For hard-to-reach spots, you can use Scotch-Brite pads.
Priming and Painting
Once the tank is prepared, it's time to prime and paint. Apply a plastic primer to the areas where the plastic of the tank is visible. After the primer dries, apply a filler (preferably a two-pack filler) and let it dry thoroughly. Sand the filler with P500/600 dry sandpaper or wet P1000 sandpaper. At this point, you can start applying your chosen colour. It is recommended to use a high-quality paint designed for plastics, such as Krylon Fusion or a two-component paint with an adhesion promoter. Apply multiple thin coats of paint, allowing each coat to dry before applying the next.
After the final coat of paint has dried, finish the tank with a clear coat. A two-pack clear coat is recommended. This will protect the paint job and provide a glossy finish. Make sure to follow the instructions on your chosen clear coat product for the best results. Once the clear coat has cured, you can reassemble the fuel tank and reattach it to your Polaris vehicle. Remember to let the paint and clear coat cure completely before filling the tank with fuel to avoid any paint damage.
It is important to note that some sources advise against coating the inside of a plastic fuel tank, as it can cause swelling and blistering. Instead, focus on properly preparing and painting the exterior of the tank. Additionally, ensure the paint and clear coat you use are suitable for use with plastic and will not react negatively to gasoline or ethanol-blended fuel.
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Frequently asked questions
First, empty the tank and let the inside dry. Remove the fuel cap and the fuel pump (or mask it with tape). Then, thoroughly degrease the paint. Dirt, grease and polish will be deep in the scratches so take your time with this step. Next, sand off the clear coat gently and remove the decal.
Some people suggest using RIT dye, which is normally used to colour clothing. First, clean your tank with a sponge, water and soap. Remove your fuel cap and any stickers or components you don't want to colour. Then, boil water and mix it with the dye in a bucket. Add the gas tank and cover the bucket with aluminium foil.
Some people recommend using a fibreglass resin mixed with the pigment colour of your choice. You can also use a car paint that has metal specs. If you are painting a polyethylene motorcycle gas tank, Ixell-adhera aids the adherence of 2-component paint on internal or external plastic material.
Bubbling occurs when fuel vapours permeate through the walls of the tank. To prevent this, some people coat the inside of the tank with an Epoxy liner like Caswell.
