Rajan Wilcox
Polishing aluminium fuel tanks can be a tedious task, but there are a variety of methods to achieve a mirror-like finish. Some prefer to use sandpaper, starting with a lower grit to remove deep scratches and progressing to a higher grit for a smooth finish. Others opt for liquid polishes, such as metal polishes or baking soda and water mixtures, which can be applied by hand or with tools like a rotary polisher or drill. Acid washing is another option, but it may dull the shine. For a cheap and effective solution, a clean piece of carpet attached to a rotary polisher or drill can also be used with metal polish.
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What You'll Learn
Sanding down the tank
Start with a coarse grit sandpaper to quickly remove any deep scratches, imperfections, or blemishes on the surface of the tank. A 240-grit sandpaper is a good starting point and will help you make quick progress. Be sure to sand evenly and with consistent pressure across the entire surface to avoid creating new scratches or an uneven finish.
Progress through the grits of sandpaper in a systematic manner. After the initial sanding with 240-grit, move to 600-grit sandpaper. This finer grit will help smooth out the scratches left by the coarser paper. Continue sanding until the majority of the scratches are gone, and the surface feels noticeably smoother.
For an even smoother finish, continue sanding with progressively finer grits of sandpaper. The next step up would be 1500-grit, which will further refine the scratches and create an even finer finish. Finally, you can use an ultra-fine 3000-grit sandpaper to remove any remaining scratches and create a surface that is ready for polishing.
After sanding, the tank should have a uniform, smooth appearance, and it is likely that the tank will already have a noticeable shine due to the fineness of the final grit. At this stage, you may choose to move on to the polishing process, or you could use a compounding pad to further enhance the finish and prepare the surface for polishing.
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Using a metal cleaning compound
Aluminium fuel tanks are corrosion-resistant, but they can still rust on the inside after a long period of use. To remove the rust, you can put a metal chain inside the tank and roll it around while rinsing the tank with water. The rolling motion of the chain will help to loosen and remove the rust.
After removing the rust, you can clean the tank with a metal cleaning compound. You can use a product like Eagle 1 A to Z Wheel Cleaner, which is strong enough to remove caked-on sludge without damaging the metal. Spray the cleaner into the tank, add a small amount of water, and let the tank soak before draining and rinsing. Alternatively, you can use a product called Alumaclean, which also works on stainless steel.
If you are looking to brighten the aluminium, you can use an aluminium brightener, which is an acid that will turn the metal white and remove any grime. However, this will also remove any existing polish, so it should not be used on polished tanks unless heavily diluted.
You can also use a rubbing compound designed for paint, or a non-abrasive metal polish such as blue magic. If you are using a power buffer, be aware that this can leave swirl marks on the surface of the tank. To avoid this, you can try using a soft cloth with liquid white polish instead.
For more heavily soiled tanks, you may need to start by using sandpaper to smooth out the surface before applying a metal polish.
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Polishing with a drill
Polishing an aluminium fuel tank with a drill requires some preparation and a few tools. First, you need to assess the condition of the tank. If there are deep scratches, you should start by using sandpaper to smoothen the surface. Start with a lower grit sandpaper, such as 240-grit, and gradually increase the grit to 600, 1500, and finally 3000. This process will help you achieve a smoother surface before moving on to polishing.
Once the surface is prepared, you can attach a clean, soft cloth or a polishing pad to your drill. Some people have suggested using a spare piece of carpet for this purpose. Apply a small amount of metal polish or a liquid metal cleaner to the cloth or pad. Make sure you follow the instructions on your chosen product and always test it on a small area first.
Now, you can start the drill and gently apply it to the surface of the tank. It is important to maintain a steady speed and pressure to avoid any inconsistencies in the finish. Move the drill in slow, circular motions, overlapping each section as you go. Take your time with this process, as rushing may result in an uneven finish.
Finally, once you have polished the entire surface, you can use a clean, soft cloth to buff the tank to a shine. This final step will remove any excess polish and help you achieve a smooth, mirror-like finish.
Polishing aluminium fuel tanks with a drill can be a cost-effective and efficient method, but it does require some patience and practice to master the technique.
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Acid washing
For the acid wash, you must first fill the fuel tank with water, and then add a cup of muriatic acid. Dispose of the contents of the tank properly and repeat this process until the wash becomes clear. You can also leave the tank overnight with a weak acid solution inside. The next day, empty the tank and wash it with water to remove any remaining chemicals and particles. Before installing the tank back, let it dry completely for at least 24 hours.
It is important to note that you must wear body protection when handling the acid wash to avoid inhaling or touching the cleaning agents. Additionally, make sure to follow the proper removal process for the fuel tank, as outlined in the vehicle or boat manual, to avoid damaging other components.
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Using a liquid polish
Polishing aluminium fuel tanks can be a dirty and time-consuming job. It is important to know the content of the product you are using and the type of metal you are using it on. For example, aluminium "brightener" is an oxidizer and should never be used on stainless steel or chrome.
If your tank is uneven and blotchy, you may want to start by soaking the tank with acid and giving it a quick scrub. Be careful not to leave the acid on for too long, as this can dull the shine. You can then use a non-abrasive liquid metal polish such as blue magic, or white diamond from Advance Auto, which has a polish and sealer in it. You can polish with the tanks filthy, and it will still work as it has a cleaner. Polish until it's black, haze dry, then buff off in the same pattern. You can use a Nevr Dull pad or a soft cloth, with some recommending a cloth baby diaper.
If your tank has deep scratches, you may need to start by using sandpaper to smoothen it out. Start with a lower grit sandpaper, such as 240, to remove deep scratches, then progress to a higher grit, such as 600, 1500, and finally 3000. You can then use a liquid metal polish to achieve a mirror finish.
Some people have had success using a spare, clean piece of carpet attached to a rotary polisher or drill, along with a metal polish, to clean up aluminium panels.
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Frequently asked questions
There are a few methods to polish aluminium fuel tanks. One approach is to start with a fine grit sandpaper (240) to remove deep scratches and then progress to a finer grit (600, 1500, and finally 3000). After sanding, use a compounding pad followed by a finishing pad with a metal polish. Alternatively, you can use a power tool such as a DeWalt DA with a metal cleaning compound or a rotary polisher/drill with a clean piece of carpet attached to it.
There are specific metal polishes such as Wolfgang Metal Polishes or One Grand Metal 300 Polish that can be used to clean and polish aluminium. For a cheaper option, you can use a Nevr Dull pad or a liquid polish like White Diamond, which also contains a sealer.
It depends on the method and products used. If you pay a professional to machine polish your aluminium fuel tanks, the results can last longer and shine better. However, if you choose to polish them yourself, you may need to re-polish every three months or so, which takes about ten minutes per tank.
