Katerina Swanson
Removing a fuel tank liner can be a tricky and time-consuming process, but it is possible to do so without losing your sanity! There are several methods that can be employed, depending on the tools you have available and the condition of the tank. The most common method involves using acetone or MEK to dissolve the liner, which can then be flushed out with a pressure washer. However, some liners are more resilient and may require a paint stripper to dissolve them. It is important to note that this process can be dangerous, as the chemicals involved are toxic and flammable, so it should be carried out with good protection and in a well-ventilated area.
Removing a Fuel Tank Liner
| Characteristics | Values |
|---|---|
| Step 1 | Start with hot water and a mild detergent (dishwashing liquid). Fill the tank with this formula, drain, and repeat. |
| Step 2 | Rinse with water and plug the petcock holes. |
| Step 3 | Add undiluted acetone, replace the filler cap, and allow the acetone to soak on all the tank surfaces for a few hours at each position. |
| Step 4 | Drain and contain the acetone and rinse the tank. Remove any debris from the reclaimed acetone. |
| Step 5 | Add the acetone again, along with a handful of nuts and bolts. Pennies are also good. You only need about 1/3 of a tank fill this time. Recap the tank. |
| Step 6 | Shake the acetone/metal cocktail. The longer and harder you shake it, the better the results. |
| Step 7 | Wash the tank several times and dry it. |
| Alternative Method | Use a pressure washer to clean the tank, then use sandpaper to remove any remaining liner. |
| Warning | Some sources suggest cutting open the tank as the only way to remove the liner. This is likely to be dangerous and should be avoided. |
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What You'll Learn
Use acetone to dissolve the liner
Removing a fuel tank liner can be a tedious task, but acetone can be an effective solvent to dissolve the liner. Here's a detailed guide on using acetone for this purpose:
Prepare the Fuel Tank:
Start by removing the fuel and any internal components from the fuel tank. This is crucial to access the liner and ensure that no fuel remains in the tank, as you will be working with potentially harmful chemicals.
Initial Cleaning:
Before using acetone, it is recommended to clean the tank with hot water and a mild detergent, such as dishwashing liquid. Fill the tank with this solution, drain it, and repeat the process. This step helps remove any residual fuel or debris that could react with the acetone.
Protective Measures:
Acetone is a strong chemical that can be aggressive on paints, finishes, and your skin and lungs. Before proceeding, ensure you are wearing appropriate personal protective equipment, including gloves, eye protection, and a solvent-specific breathing mask.
Apply Acetone:
Now, you're ready to use acetone. Plug the petcock holes and add undiluted acetone to the tank. Replace the filler cap. It is important to ensure that all surfaces of the tank are immersed in the acetone. Leave the acetone to soak for several hours.
Rotate and Soak:
To ensure even coverage, rotate the tank periodically during the soaking process. This can be done by placing the tank in a bathtub and rotating it every few hours. This step helps ensure that the acetone dissolves the liner from all areas of the tank.
Drain and Rinse:
After soaking, drain the acetone from the tank and collect it in a container. It is important to properly dispose of the used acetone, as it will contain dissolved liner material. Rinse the tank with water to remove any remaining acetone residue.
Repeat if Necessary:
Depending on the condition of your tank and the liner, you may need to repeat the acetone soaking process. If there are still liner remnants, refill the tank with acetone, following the previous steps, and allow it to soak again.
Final Cleaning:
Once you're satisfied that the liner has been removed, give the tank a final clean. You can use warm soapy water and then air-dry the tank. Make sure the tank is completely dry before proceeding with any further treatments or refilling it with fuel.
Remember, always work in a well-ventilated area when using acetone, and take the necessary precautions to protect your health and safety.
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Wash the tank with hot water and detergent
To wash the tank with hot water and detergent, you will need a hose that runs clean, hot tap water, and a safe fuel-system detergent. If you don't have access to a hose with hot water, you can attach a rubber hose to a sink faucet and run the water hot.
Once you have hot water in your fuel tank, aim at the sides while filling the bottom. Add a little detergent and coat the inside of the tank, but don't fill it yet. Swirl your fuel tank to dislodge any remaining fuel and sediment that has collected at the bottom. The hot water and detergent will help break up the thicker buildup.
Dump the contents of the tank into a pan, being sure to collect all the liquid, as it is toxic and should not be allowed to run free. You can use a brush to loosen debris from the sides of the tank if your fuel tank design makes it possible. Repeat this process until the gas tank appears clean when empty and illuminated.
When the fuel tank appears to be fully clean, rinse it with hot water twice more, focusing on coating the sides so that all the detergent is rinsed out. Use a lint-free cloth to wipe down the outside and apertures of the fuel tank. Shake out the tank and remove any moisture from areas you can reach with the cloth.
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Remove liner debris
Removing the liner debris from a fuel tank can be a challenging task, but with the right tools and techniques, it can be accomplished effectively. Here is a detailed guide to help you through the process:
Start by removing as much of the fuel and internal components from the tank as possible. This will give you better access to the liner debris and reduce the risk of any accidental damage to the other components. Once the fuel and most parts have been removed, use a pressure washer to clean the tank. This will help dislodge any large pieces of liner debris and grime buildup.
After pressure washing, use sandpaper to manually remove any remaining liner debris that the pressure washer couldn't reach. Be thorough and patient during this step, as it is important to remove as much of the liner debris as possible before proceeding to the next steps. Once you have sanded the accessible areas, use a shop vacuum to remove the debris that has been loosened or dislodged during the process.
Next, create a mixture of drywall screws and acetone, and slosh it around inside the tank. This mixture will help break up any remaining liner debris that couldn't be removed manually. The screws act as abrasive agents, scraping away at the liner as the mixture is agitated. After agitating the mixture, drain and rinse the tank, and you should start to see chunks of the old liner coming out. Remove any debris from the reclaimed acetone before moving on to the next step.
Now, repeat the acetone treatment, but this time, add a handful of nuts and bolts, or even pennies, to the acetone. You won't need as much acetone this time, just enough to cover about one-third of the tank. Securely replace the filler cap and vigorously shake the tank. The longer and harder you shake it, the better the results will be. Aim to shake the tank for at least an hour, then let it sit overnight, rotating it occasionally.
Finally, shake the tank once more the next day, and then drain and rinse it thoroughly. This process should effectively remove the majority of the liner debris, leaving your fuel tank clean and ready for any necessary repairs or maintenance. Remember to always exercise caution when working with flammable materials and follow proper safety procedures.
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Sand the tank
Sanding the tank is a crucial step in removing the fuel tank liner. It is an effective way to manually remove any remaining liner residue after the initial cleaning process. Here is a detailed guide to help you through the process:
Start by equipping yourself with the right tools and safety gear. You will need a suitable type of sandpaper for the task. The grit size and type of sandpaper can vary depending on the condition of your tank and the liner. It is recommended to start with a medium to fine grit sandpaper, as coarse grits may leave deeper scratches on the metal. Ensure you wear protective gear, including gloves, eye protection, and a respirator, as the process will generate dust and debris.
Begin sanding the interior of the tank. If your fuel tank has a large fuel pump access hole, take advantage of it to reach inside with the sandpaper. Work systematically, covering all surfaces of the tank. Pay close attention to areas where the liner may be thicker or more stubborn to remove. Use a gentle back-and-forth motion with the sandpaper, applying even pressure. Be thorough, but also be cautious not to damage the metal surface of the tank excessively.
As you sand, periodically check your progress and remove any debris that accumulates inside the tank. A shop vacuum can be useful for this purpose, as it can reach inside and suction out the loose liner particles and dust. Removing the debris frequently will give you a clearer view of your work and help you assess which areas may need more attention.
Once you are satisfied that you have removed as much of the liner as possible with the sandpaper, you can move on to the next step, which typically involves using a chemical solvent, such as acetone, to dissolve any remaining liner residue. Remember to be patient throughout the process, as removing a fuel tank liner can be a time-consuming and tedious task.
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Pour in a new liner
Once you have removed the fuel and internal components from the tank, it is time to clean the tank. A pressure washer works well for this. After washing, dry the tank. Then, use sandpaper to manually remove any remaining liner debris. After sanding, use a shop vac to remove any remaining debris. Next, add drywall screws and acetone to the tank. Slosh this mixture around to break up what you couldn't reach by hand.
Now, it's time to pour in the new liner. First, ensure that the liner you are using is suitable for your tank—some liners are not designed for use in aircraft oil tanks or tanks with plastic components, and some are not suitable for tanks containing liquids above a certain temperature. Always read the manufacturer's instructions and safety information before use.
When you are ready to begin, pour the liner into the tank and coat the entire inner surface by slowly rotating the tank in all directions. When all surfaces have been completely coated, a generous excess should remain. Let the tank stand for 8–10 minutes with the spout open, then close the spout and slowly rotate the tank, allowing the excess to re-coat all surfaces. Let the tank stand for an additional 8–10 minutes with the spout open, but this time, on a different side. Repeat this process until the tank has the desired coating, ensuring that the coating does not drain to one area and dry. Drain off any excess coating for later use.
Finally, drain any remaining excess and remove all stops. Allow the tank to air-dry in a well-ventilated area for at least 24 hours. For extra protection, air-dry the first coat for 6 hours or longer and repeat the coating process.
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Frequently asked questions
The first step is to fill the tank with hot water and a mild detergent, then drain and repeat.
After the first wash, rinse the tank with water, plug the petcock holes, and add undiluted acetone. Allow the acetone to soak for several hours.
Drain and rinse the tank again. You should see chunks of the old liner coming out. Then, add the acetone a second time, along with a handful of nuts and bolts or pennies.
Recap the tank and shake the acetone and metal pieces together for as long as possible. The longer you shake, the better the results.
