Ameer Randolph
Refurbishing a fuel tank can be a challenging task, requiring careful inspection, cleaning, and sealing to ensure optimal performance. Fuel tanks, especially those left unused for extended periods, are susceptible to rust and corrosion, which can lead to fuel contamination and filter blockage. To refurbish a fuel tank, it is essential to start by draining the tank, inspecting for damage, and removing any rust or debris using mechanical or chemical methods. This process may involve disassembling the tank, cleaning with solvents or steam, and ensuring the tank is thoroughly dried. Once cleaned, sealing the tank with a suitable product, such as a specialized fuel tank sealer, helps prevent future rust and corrosion. Reassembly and painting can then be undertaken, followed by thorough testing to ensure the tank's integrity and functionality.
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What You'll Learn
Removing rust and scale
Before beginning any work on a fuel tank, it is important to take safety precautions. Always disconnect the battery before working on a fuel system, as old tanks can still harbour flammable vapours. Even wire-brushing can cause sparks, so always work in a well-ventilated area, preferably outside, and have an extinguisher on hand.
Now, to remove rust and scale from a fuel tank, you will need to follow these steps:
Firstly, drain the tank of any remaining fuel. This is important, as even a small amount of fuel can contaminate your cleaning process and create a fire hazard. Depending on the size of your tank, you may be able to siphon the fuel out, or you may need to use a pump. Once the tank is empty, it is a good idea to rinse it with water to remove any fuel residue.
Next, you will need to remove any rust and scale from the interior of the tank. There are several methods you can use for this:
- Chemical rust removers: These are commercially available and can be effective in treating substantial corrosion.
- Mechanical cleaning: Using a stiff brush, nylon scouring pad, or even gravel, you can scrub the interior of the tank to remove rust and scale. This can be done by hand or with the aid of a drill or angle grinder.
- Steam cleaning: This method can be effective but may require the services of a professional radiator or truck repair shop.
- Ospho rust converter: This product can be sprayed onto the interior surfaces of the tank and will convert rust and stabilise the metal.
Whichever method you choose, the goal is to remove as much rust and scale as possible. It is likely that you will need to repeat the process several times to achieve a thorough cleaning.
Finally, once you are satisfied that the interior of the tank is clean and free of rust, it is important to neutralise any remaining rust and prevent future corrosion. This can be done by sealing the tank with a specialised product, such as the KBS Coatings sealer or the POR 15 Fuel Tank Sealer. These products create a non-porous, rust-stopping barrier that is impervious to fuel.
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Sealing the tank
First, it is essential to clean the tank thoroughly. Use a stiff brush, a nylon scouring pad, or even steam cleaning to remove any dirt, grime, and rust from the interior and exterior surfaces. It is crucial to be meticulous during this step, as any remaining residue or rust can compromise the effectiveness of the sealant.
Next, inspect the tank for any signs of corrosion or damage, especially around the seams and plumbing. If there is substantial corrosion, treat it with a chemical rust remover. It is also important to ensure that the tank is completely dry before proceeding to the next step.
Now, it's time to apply the sealant. There are various sealants available on the market, such as the KBS Coatings sealer or the POR 15 Fuel Tank Sealer. The latter is known for its compatibility with modern petrol and its ability to create a non-porous, rust-stopping barrier. Before applying the sealant, be sure to follow the manufacturer's instructions for proper mixing and preparation.
Once the sealant is ready, pour it into the tank. Then, tilt, jolt, and spin the tank to ensure that the sealant coats all interior surfaces evenly. This step is crucial to prevent any pooling or settling of the sealant, ensuring a thorough application. After the sealant has been applied, drain any excess from the tank and leave it to air dry for at least 96 hours to allow the sealant to cure completely.
During the curing process, it is essential to ensure proper ventilation and take the necessary safety precautions. Avoid any activities that may create sparks, such as wire-brushing, and always have a fire extinguisher nearby as a safety measure.
Finally, after the curing process is complete, inspect the tank once more for any leaks. This step is crucial to ensure that the tank is safe to use and that your refurbishment efforts have been successful.
By following these detailed steps for sealing the tank, you can effectively refurbish a fuel tank, ensuring its longevity and safe operation.
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Painting the exterior
Firstly, ensure the fuel tank is completely empty and free of any fuel traces. This step is crucial as working with flammable substances can be dangerous. Once empty, use a wire brush or scraper to remove any rust or debris from the exterior surface. It is important to be thorough in this step to create a smooth base for painting.
Next, clean the exterior of the fuel tank with a suitable degreaser or cleaner. This will remove any remaining contaminants and ensure the surface is ready for painting. After cleaning, give the tank a thorough wipedown using a pre-painting prep solution. This will help prepare the surface for an even and durable coat of paint.
Now, it's time to select the right paint for the job. Chassis paint is often recommended for fuel tanks as it provides a thick and resilient coating. Brushes are typically used to apply chassis paint, ensuring a nice finish. Carefully follow the manufacturer's instructions for the paint you have chosen, including any recommended drying times between coats.
When painting, pay close attention to the fuel tank's fittings and connections. Seal these areas with duct tape before painting to avoid any paint blockage or overspill. It is also important to ensure the tank is well-ventilated during the painting process to allow for the release of any fumes.
Finally, allow the paint to dry thoroughly before reassembling the fuel tank and refilling it with fuel. This process may take several hours or even days, depending on the paint used and environmental conditions. Always refer to the paint manufacturer's instructions for specific drying and curing times.
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Disconnecting the tank
First, disconnect the wires to the fuel gauge's sender and gently remove the unit and float assembly. Then, undo the pick-up pipe and carefully remove it from the tank. If your vehicle has a breather pipe, locate and disconnect it.
The next step is to disconnect the tank from its filler assembly. This process can vary depending on the vehicle. For classic cars with a fixed filler that passes through the bodywork, you will need to remove the cap's mechanism, typically attached with a small grub screw. Take care to preserve any seals, rubber collars, or hose clamps during this process.
Support the tank before freeing it, as it will be heavier than it looks. Most tanks are secured by steel straps or bolted directly to the body. Undo the fixings and lift or lower the tank out.
Once the tank is disconnected and removed, you can begin the process of cleaning and treating any corrosion or rust.
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Using a fuel stabiliser
Fuel stabilisers are a great way to preserve fuel in your tank, especially if you are storing a vehicle for a long period. They are chemical additives designed to preserve the quality of gasoline or other fuels when stored for extended periods. They keep fuel fresh and effective for at least two years of storage time.
Fuel stabilisers are suitable for all kinds of gasoline and diesel engines, including two-stroke motors found in chainsaws, snowmobiles, and certain water pumps. They are also suitable for classic cars, lawnmowers, and other equipment. The optimal time to add a fuel stabiliser is when fuelling up, especially if the vehicle or equipment will be stored for 30 days or more. It is important to note that fuel stabilisers work best when added to fresh fuel. If you are adding a stabiliser to a full tank of old fuel, it may not be as effective in restoring the gasoline to new.
To use a fuel stabiliser, first, ensure there is fresh fuel in the tank. The tank should be about 95% full. Then, measure the correct amount of stabiliser to add. The directions on the bottle will tell you how much to add for a given amount of fuel. For example, STA-BIL® fuel stabiliser should be added at 1 ounce per 2.5 gallons of fuel. Pour the stabiliser into the tank and replace the gas cap. Finally, run the engine for about 5-10 minutes to ensure the stabilised fuel circulates throughout the fuel system.
It is recommended that a stabiliser be used every time the fuel in the tank is cycled, meaning treating when the fuel is completely replaced (run almost empty and refill). Adding a stabiliser every time the tank is topped off is not necessary. This will help to keep the fuel as fresh as possible and to keep the fuel system clean, especially during infrequent use.
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Frequently asked questions
If your fuel tank is rusty, it will need to be refurbished. Rust can cause petrol leaks, which are dangerous, and can contaminate the petrol with rust particles, which will block fuel filters.
First, drain the tank of any fuel and disconnect the wires to the fuel gauge's sender. Then, use a stiff brush or a nylon scouring pad on a drill or an angle grinder to remove any rust. You can also use a chemical rust remover. Once the tank is clean, seal it with a tank sealer to prevent future rust.
You will need a fuel tank restoration kit, which includes a degreaser, a sealer, and a rust remover. You will also need a new fuel gauge sender and a fuel pickup. Other products you may need include duct tape, a wire brush, a scraper, and a fuel stabiliser.
