Rajan Wilcox
Diesel fuel tanks are prone to leaks and holes due to ongoing use, even small pinhole leaks can cause significant damage if left unrepaired. There are several ways to repair a diesel fuel tank, including welding, rebarrelling, and using a repair kit. The best method depends on factors such as the material of the tank, the extent of the damage, and the required ongoing use of the tank. Repair kits, such as the Edwards and Cromwell Kit F-1 First On-scene Leak Repair Kit, are designed for quick, temporary repairs, especially in emergency situations. For long-term repairs, welding or rebarrelling may be more suitable, but these processes can be dangerous and should be performed by trained professionals.
Diesel Fuel Tank Repair Methods
| Characteristics | Values |
|---|---|
| Repair kits | AP Products Versachem 90180 Heavy-Duty Fuel Tank Repair Kit, First Responder Diesel Fuel Tank Repair Kit F-1 |
| Repair kit features | Absorbent pads, wooden plugs, rubber mallet, epoxy repair putty, Plug N' Dike, football and golf ball plugs |
| Repair kit effectiveness | Mixed reviews, some report complete sealing of leaks, others report leaks remaining or reappearing |
| Welding | Can be dangerous if not done in a controlled environment, but can last a few years |
| Rebarelling | Best option for long-term use, involves cutting off end caps and removing old barrel, then welding the end caps onto a new barrel |
| Tank replacement | Best option if the tank is beyond repair, or has too many leaks/holes |
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What You'll Learn
Repair kits for quick, temporary fixes
The Edwards and Cromwell Kit F-1 First On-scene Leak Repair Kit is designed for first responders who are first on an accident scene to make quick smaller tank leak repairs. The kit includes wooden dowels and wedges (wooden plugs) that can be inserted with a rubber mallet to quickly stop the flow of liquid from punctures or cracks. The kit also includes Plug N' Dike, which expands upon contact with fuel to form a temporary barrier. The First On Scene Kit also includes absorbent pads that can soak up spilled fuel to prevent environmental contamination and fire hazards.
The AP Products Heavy-Duty Fuel Tank Repair Kit 002-90180 is another option for repairing diesel fuel tanks. This kit is suitable for gasoline and diesel fuel tanks and can withstand temperatures from 40°F to 200°F. It can be used to repair pinholes, rust-outs, hairline cracks, and holes up to 1/2" in diameter. The repair process involves draining the tank or using the enclosed yellow mastic stick to temporarily stop the leak, sanding the area, cutting fiberglass cloth to size, and mixing and applying the repair epoxy. This kit can be purchased from Home Depot.
The Versachem Heavy-Duty Fuel Tank Repair Kit is a third option for repairing diesel fuel tanks. This kit has received mixed reviews, with some customers reporting complete sealing of leaks while others found that it did not stop leaks or that the patch started leaking. It is important to note that this kit is only suitable for temporary repairs on plastic fuel tanks, as the patch can crack and leak after the tank deforms from refills and driving. This kit can be purchased from Amazon.
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Welding as a long-term solution
Welding is a long-term solution for repairing diesel fuel tanks. However, it can be dangerous if not done in a controlled environment. There is a risk of fire from diesel fumes and other dangers to the welder, as welds often need to be done inside the tank. It is recommended to seek out a specialised welder who is trained in welding fuel tank seams and other challenging areas. These professionals can weld both aluminium and steel fuel tanks.
The first step in the welding repair process is to identify the leak. This can be done through a rigorous water testing process. Once the leak is identified, the correct material for the repair can be determined. If the tank is to be used for long-term, ongoing use, rebarrelling may be the best option. This involves cutting off the end caps of an old aluminium fuel tank and removing the old, corroded middle part. A new aluminium barrel is then rolled, and the old end caps are welded back on. All fittings are transferred to the new tank, which is then pressure tested.
When welding a diesel fuel tank, it is important to ensure that the tank is drained and that the metal is cleaned and prepared. One user reported using a MIG welder instead of a TIG welder due to limited space. However, they experienced leaks beside the welds, which could be due to a lack of fusion or rusty, pitted metal inside the tank. To address this, it is recommended to add more plating over the old skin, extending past the pitted areas, or to cut out and replace the pitted areas with larger, new plating.
It is worth noting that some people have expressed concerns about the safety of welding diesel fuel tanks, especially with fuel still in them. In some cases, it may be necessary to drain the fuel and take precautions to avoid exposure to fumes. Overall, welding can be an effective long-term solution for repairing diesel fuel tanks, but it requires careful preparation, the right equipment, and adherence to safety protocols.
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Rebarelling for old, corroded tanks
If you have an old diesel fuel tank that has seen better days, rebarrelling might be the best option to get it back into action for the long term. This process is particularly useful for older tanks that have suffered extreme use and are heavily corroded.
Firstly, the end caps of the old aluminium fuel tank are cut off, and the corroded middle part, or barrel, is removed. A new aluminium barrel is then rolled out, and the old end caps are welded back on. All fittings are transferred over to the new tank, and it is then pressure tested to ensure there are no leaks.
This process can extend the life of your original fuel tank by several years. It is a specialist job, and it is recommended to seek out expert mechanics or welders who are trained in welding fuel tank seams and other tricky areas. These professionals will be able to test and assess the situation and advise on the best course of action.
In addition to rebarrelling, some companies offer custom wet kits. This involves technicians putting a divider into a fuel tank, allowing one part to hold oil for hydraulics, and the other part to hold diesel fuel.
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Custom aftermarket replacements
If you are looking for custom aftermarket replacements for your diesel fuel tank, there are a few options available.
Transfer Flow, Inc. offers a range of aftermarket fuel tank systems that are legal across all 50 states. Their products are designed to fit specific vehicles, such as the Ford Transit 350 Van, Toyota Tundra, and Ram cab chassis. Transfer Flow's tanks are made in the USA from high-quality American-made steel and come with a 6-year unlimited-mile warranty.
Another option is Zip's AW Direct, which offers high-capacity, baffled aftermarket fuel tanks for light-duty pickups and service vehicles. Their tanks meet federal requirements and include mounting hardware. Zip's also offer a Transfer Flow 40-gallon refueling tank system that is legal to carry and transfer diesel, gasoline, and kerosene. This tank is designed to fit under most tonneau covers and in the bed of light and heavy-duty trucks. It is made from 12-gauge ReliaSteel, high-yield U.S. aluminized steel, and is powder-coated black for a durable finish.
For those seeking a unique tank system that can hold two different types of fuel, Zip's also offers a 50/50 split refueling tank system. This system is legal to carry and transfer gasoline, diesel, methanol/ethanol, and kerosene. It features a hose-purge function that eliminates messes by pulling fuel left in the hose back into the tank. The tank is made from 12-gauge ReliaSteel and is powder-coated black for durability.
If you are repairing your diesel fuel tank, rebarrelling may be an option if your tank is old and has seen extreme use. This process involves cutting off the end caps of the old aluminum fuel tank and removing the corroded middle part. A new aluminum barrel is then rolled and the old end caps are welded back on.
When considering custom aftermarket replacements for your diesel fuel tank, it is important to choose an option that suits your specific vehicle, usage needs, and local legal requirements.
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Repair based on tank material, age and use
The best way to repair a diesel fuel tank depends on the material, age, and intended use of the tank.
If your tank is made of metal, you can use a heavy-duty fuel tank repair kit to fix holes and cracks. These kits usually include epoxy, sandpaper, fiberglass cloth, and an application brush. The repair process is straightforward and can be completed in less than 20 minutes. However, this method may not be suitable for plastic fuel tanks as the epoxy patch may crack and leak after the tank deforms from refills and driving.
For aluminum or steel fuel tanks, welding is an option, but it can be dangerous if not done in a controlled environment due to the risk of fire from diesel fumes. It is recommended to have specialized welders perform the repair to ensure it is done safely and effectively. The process involves rigorous water testing to identify the leak, welding with the appropriate material, and pressure testing to ensure there are no remaining leaks.
If your fuel tank is older and has seen extreme use, rebarrelling may be the best option for long-term use. This process involves cutting off the end caps of the old aluminum tank, removing the corroded middle part, and welding the old end caps onto a new aluminum barrel. All fittings are then transferred to the new tank, which is pressure tested.
The age and intended use of the tank are also important factors to consider. If your tank is new and only occasionally used, repairing it may be a more cost-effective solution than replacing it. However, if the tank is beyond repair or has multiple leaks and holes, replacing it may be the best option.
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Frequently asked questions
The best method depends on the material your fuel tank is made of, how often you use it, and how old it is. If your tank is beyond repair, you may need to replace it. Otherwise, you can try welding it or using a fuel tank repair kit.
The F-1 Kit is a compact kit for first responders who are first on the scene of an accident. It's designed to quickly stop leaks, especially fuel spills. It includes wooden plugs, a rubber mallet, epoxy repair putty, absorbent pads, and Plug N' Dike, which expands upon contact with fuel to block the flow.
The AP Products Versachem 90180 Heavy-Duty Fuel Tank Repair Kit has received positive reviews for its ease of use and ability to seal leaks in tanks with dripping holes. However, some customers have reported that it doesn't work on plastic fuel tanks.
