Regan Brown
Refinishing a fuel tank is a great way to extend its life and improve the appearance of your vehicle. The process involves cleaning, polishing, and painting or coating the tank. It is important to start with a smooth, clean surface by removing any rust, corrosion, or flaking paint. This can be achieved through an acid wash or by manually sanding and polishing the tank. Once the surface is prepared, you can choose to paint or coat the tank to protect the metal and achieve the desired aesthetic. Some popular options include mirror polishing, powder coating, vinyl wraps, and stainless steel wraps. Properly sealing the tank is also crucial to prevent rust and ensure the longevity of the refinish.
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What You'll Learn
Cleaning and polishing
The first step is to drain the fuel tank. This can be done by turning off the tank fuel petcock and removing the tank from the motorcycle. Use tubing to drain the fuel into a container, and consider using a coffee filter in a funnel to capture any particles. Once the tank is drained, it should be thoroughly cleaned. If there is rust or corrosion present, an acid wash can be used to loosen and remove the damaged material. Acid washes can clean both the interior and exterior of the tank. After the acid wash, the tank should be rinsed with water and dried.
If the tank is made of aluminium, it is important to use an acid-based etching primer to prepare the surface for painting. This will help the paint to adhere properly and create a durable finish. Sanding may also be necessary to smooth the surface and remove any remaining rust or corrosion.
Once the tank is clean and dry, polishing can begin. Polishing can be done by hand or with a buffing wheel. It is important to use the correct type of polishing compound for the material of the tank. For example, aluminium tanks require a different type of compound than steel tanks. The tank should be polished to a high shine, removing any scratches or imperfections.
After polishing, the tank may be coated or painted to protect the surface. Powder coating is a popular option, as it provides a durable and corrosion-resistant finish. Painting the tank is also an option, but it is important to use a paint that is compatible with the material of the tank and will adhere properly. Vinyl wraps can also be used to cover the tank, but they may not be as durable as other options and can allow moisture to seep in, leading to rust and corrosion.
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Acid wash and sanding
When refinishing a fuel tank, it is important to start with a clean and smooth surface. An acid wash can help loosen damaged material, rust, and corrosion before sanding and polishing.
Muriatic acid, which is about 33% hydrochloric acid, is often used for this purpose. It is a potent substance that can effectively clean both the interior and exterior of a fuel tank. However, it requires careful handling due to its corrosive nature and vapours. It is recommended to use muriatic acid in a well-ventilated area and to neutralize it with baking soda or laundry powder after treatment. An alternative to muriatic acid is an electrolytic bath, which removes rust without the same level of aggressiveness.
Before using any acid, it is important to drain the tank and remove any residual fuel, particles, and chemicals. One method is to use tubing to drain the tank into a container with a coffee filter in a funnel to capture particles. Waxing the surface of the tank, especially near the gas cap and petcock valve, can also help protect the surrounding paint and make cleanup easier.
After the acid wash, the next step is sanding. It is important to start with fine-grit sandpaper and work your way up to avoid deep scratches that will be difficult to remove. For plastic tanks, it is recommended to use an emery cloth or steel wool, starting with finer grades to avoid scratches that cannot be buffed out. For metal tanks, a range of sandpaper grits from 320 to 600 can be used, progressing to finer grits as the surface becomes smoother.
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Painting and coating
Start by cleaning and polishing the fuel tank to create a smooth and clean surface for the paint or coating to adhere to. Remove any flaking paint, rust, or corrosion, as these can interfere with the adhesion of the new finish. For tanks with extensive surface rust, corrosion, and pitting, consider using an acid wash to loosen the damaged material before sanding and polishing. Acid washes can effectively clean both the interior and exterior of older and well-used fuel tanks.
Once the tank is clean and smooth, you may want to apply a primer to ensure better adhesion of the paint. An acid-based etching primer is particularly useful for preparing the surface of cleaned and polished aluminium to bond with quality paint. You can also use an etching primer to prepare other metal surfaces, such as steel, for painting.
When choosing a paint for your fuel tank, opt for a type of paint that will provide a thick and resilient coating, such as chassis paint. You can also use a fuel tank repair kit, which includes all the necessary steps and materials for preparing and painting your fuel tank. If you want a mirror-like finish, consider using a product like Eastwood's Tank Tone, which will give your tank a bright zinc finish.
In addition to painting, you may also consider powder coating your fuel tank. Powder coating is a great option if you want to spend less time maintaining your vehicle, as it provides a durable and protective finish that will keep your fuel tank looking like new. Vinyl and stainless steel wraps are another popular option for enhancing the appearance of your fuel tank, but they may not offer the same level of protection as paint or powder coating.
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Replacing the fuel pump
Refinishing a fuel tank typically involves cleaning, sealing, and painting the tank to restore its appearance and functionality. While the process can vary depending on the condition and type of fuel tank, replacing the fuel pump is often recommended as part of the refinishing process. Here is a step-by-step guide on replacing the fuel pump during a fuel tank refinish:
Step 1: Assess the Fuel Pump Condition
Before replacing the fuel pump, it is essential to evaluate its condition. In some cases, the fuel pump may still be in good working order, and replacement may not be necessary. However, if the fuel pump has been exposed to rust particles or is faulty, replacement becomes advisable to ensure optimal performance.
Step 2: Drain the Fuel Tank
Before initiating any repairs or replacements, it is crucial to drain the fuel tank completely. This step ensures your safety and allows for a more accessible and efficient replacement process. Turn off the tank fuel petcock and remove the tank from the vehicle. Use tubing to drain the fuel into a suitable container, and consider using a coffee filter in a funnel to capture any particles.
Step 3: Disconnect the Old Fuel Pump
Locate the fuel pump and carefully disconnect it from the fuel lines, electrical connectors, and any mounting brackets or fasteners. Take note of the routing of the fuel lines and electrical wiring to facilitate proper installation of the new fuel pump.
Step 4: Clean and Inspect the Fuel Tank
With the old fuel pump removed, take the opportunity to thoroughly clean and inspect the fuel tank. Remove any traces of old fuel, rust particles, or debris from the tank using a specialized cleaner or degreaser. Ensure that the tank is completely dry before proceeding to the next step.
Step 5: Install the New Fuel Pump
Acquire a compatible replacement fuel pump that meets the specifications of your vehicle. Carefully position the new fuel pump in the same location as the old one, ensuring correct alignment and secure connections. Reattach the fuel lines and electrical connectors, following the routing observed during the disassembly process.
Step 6: Testing and Reassembly
Once the new fuel pump is installed, perform a thorough inspection of the fuel tank and its connections. Check for any signs of leakage or damage and ensure that the fuel pump is securely mounted. Prime the fuel pump according to the manufacturer's instructions and test the vehicle to ensure it is functioning correctly.
By following these steps, you can effectively replace the fuel pump during the process of refinishing your fuel tank. Remember to consult vehicle-specific repair manuals or seek professional guidance if you encounter any challenges or complexities during the replacement process.
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Sealing the tank
Sealing a fuel tank is an important step in the refinishing process, ensuring that the tank is protected from future corrosion and rust. Before sealing, it is crucial to thoroughly clean the tank, removing any traces of fuel, dirt, rust, or corrosion. This can be done using an acid wash or a specialised degreaser, such as the one included in the POR 15 kit. A leaf blower can be used to speed up the drying process.
Once the tank is clean and dry, it is ready for sealing. A specialised sealer, such as the Gold Standard Tank Sealer from KBS Coatings, can be used to effectively seal and neutralise any remaining rust. It is important to properly mix the sealer to ensure that all materials are combined thoroughly. After mixing, pour the entire contents into the tank. Tilt, jolt, and spin the tank to ensure that the sealer reaches all interior areas and to prevent pooling or settling.
Allow the sealer to dry and cure for at least 96 hours before adding fuel. During this time, you can prepare the exterior of the tank by polishing, painting, or coating it. Polishing can give the tank a high-end chrome look, but it requires regular maintenance. Painting or powder coating offers a more durable and low-maintenance option, providing a protective layer over the metal.
If you plan to paint the tank, proper surface preparation is key to achieving a good bond and finish. For aluminium tanks, an acid-based etching primer can be used to prepare the surface for paint. Alternatively, you can use vinyl or stainless steel wraps to enhance the appearance of your fuel tank. However, it is important to note that vinyl wraps may allow moisture to seep in, leading to rust and corrosion.
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Frequently asked questions
First, drain the tank of any remaining fuel. Next, clean the exterior of the tank, especially the area around the fuel level sender. Then, use a rust remover to address any surface rust and scale inside the tank. Finally, seal the tank with a tank sealer to neutralize any remaining rust and prevent further corrosion.
To clean a fuel tank, you can use a combination of rust remover, metal etch/cleaner solutions, and a sealer. You can also use a wire brush or scraper to remove any built-up dirt or grime. If you're cleaning a classic car fuel tank, you can use a degreaser like the POR 15 kit to remove old fuel and residue from the inside of the tank.
To seal a fuel tank, you can use a tank sealer like the Gold Standard Tank Sealer from KBS Coatings. Make sure to properly mix the contents before pouring them into the tank. Then, tilt, jolt, and spin the tank so that the sealer reaches all interior areas.
Yes, you can paint a fuel tank. It is recommended to use an acid-based etching primer to prepare the surface of the tank before painting, especially if the tank is made of aluminum. Chassis paint provides a thick and resilient coating.
One sign that your fuel tank needs to be refinished is if you notice that your petrol is contaminated with rust particles. Larger particles may block your fuel filters, while smaller particles may clog jets in the carburetor. If the corrosion has completely penetrated the tank's structure, you may experience petrol leaks.
