Katerina Swanson
Rust in a fuel tank can be a serious issue, potentially causing costly repairs if left untreated. The good news is that there are several methods for removing rust from the inside of a fuel tank. The most suitable method will depend on the severity of the rust and the tools available. Common approaches include using chemical treatments such as vinegar, Evaporust, or muriatic acid, mechanical methods such as shaking the tank with nuts or gravel, or electrolysis, which involves using an electric current to remove rust from metal surfaces. After removing the rust, it is important to coat the inside of the tank with a suitable product, such as Red-Kote, to prevent future rusting.
Removing Rust from Inside a Fuel Tank
| Characteristics | Values |
|---|---|
| When to coat the tank | When the tank is rust-free and dry |
| Coating product | Red-Kote, Kreem Coat |
| Coating process | Plug holes with rubber plugs, corks, or masking tape. Pour enough product to coat the tank, reinstall the gas cap and rotate the tank to ensure even coverage. Drain excess product |
| Preventing rust | Coating the tank is a long-term solution to prevent rust from returning |
| Rust removal products | Evaporust, strong vinegar (30%), diluted muriatic acid, apple cider vinegar, Krud Kutter, Sea Foam, BBs, nuts, bolts, gravel, baking soda |
| Rust removal methods | Electrolysis, using a rubber hose, spinning the tank, shaking the tank, rotating the tank |
| Safety hazards | Gas leaks due to corrosion can be hazardous to your lungs and can enter the bloodstream |
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What You'll Learn
Using nuts and bolts to remove loose rust
Removing rust from inside a fuel tank is a necessary skill for restoring old vehicles. Rust in the fuel tank can travel and create problems for your carburettors, petcock, and fuel pump, potentially leading to costly repairs.
One method for removing loose rust from inside a fuel tank is to use nuts and bolts. First, remove the gas tank from the motorcycle, then drain the fuel using the manufacturer's recommended method. Next, fill the tank with a rust remover such as vinegar or diluted muriatic acid. Add water to the top, and let it sit for a couple of hours. After this initial soak, drain the tank and fill it with loose nuts and bolts or gravel—any small abrasive will work. Add some water and shake the tank vigorously for several minutes to scrub off stubborn rust. Drain the tank and refill with vinegar or acid for a second soak. Drain and rinse well with water, then neutralise the acid with baking soda. Finally, let the tank dry and verify the amount of rust removed.
Nuts and bolts are a preferred option for removing loose rust because their sharp edges scrape the rust better. However, it is important to leave the tank in a different position each day and give it a good shake to ensure all areas are treated.
After removing rust, it is important to seal the cleaned surface to prevent rust from returning. One option is to use a product like Red-Kote, which has strong adherence and longevity.
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Soaking in vinegar and water
Vinegar is an effective method for removing rust from a fuel tank. It is a safer alternative to using muriatic acid and is easier to use, as it does not produce fumes.
To begin the process, fill the tank with vinegar, adding water to fill it to the top. Leave the mixture to soak for at least 24 hours, or even a couple of days. The length of time will depend on the severity of the rust. It is recommended to leave the tank in a different position each day and give it a good shake.
After the initial soak, drain the vinegar and fill the tank with loose nuts and bolts, gravel, or small steel balls. Add some water and shake the tank vigorously to scrub off any remaining rust. Drain the tank again and refill with vinegar for a second soak.
After the second soak, drain the tank and rinse it thoroughly with clean water. The water should be mixed with baking soda to neutralise the vinegar. It is important to ensure all the vinegar is removed to prevent flash rusting.
While vinegar is an effective method, it can take a long time and may need to be repeated. It is also important to note that vinegar can react with rubber, so it should be avoided if there are any rubber fuel lines or fittings in the tank.
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Soaking in diluted muriatic acid
Muriatic acid is a potent rust remover that can be used to clean the inside of a fuel tank. However, it is a harsh chemical that can damage the metal of the tank and should be handled with caution.
To use diluted muriatic acid to remove rust from the inside of a fuel tank, follow these steps:
Preparation
Begin by removing the fuel tank from the vehicle and setting it upright with the fuel cap off. It is important to wear protective gear, such as gloves and eye protection, and ensure the work area is well-ventilated due to the fumes produced by the acid.
Cleaning
Pour diluted muriatic acid into the tank, ensuring there is enough to slosh around. Tip and roll the tank around so that the acid covers the interior surfaces. Check the progress periodically through the filler opening. If necessary, add more acid to maintain the desired level.
Neutralizing and Rinsing
Once you are satisfied with the level of rust removal, neutralize the acid with baking soda and warm water. Flush the tank with warm water to remove any remaining acid residue.
Post-Treatment
After rinsing, the tank should be dried thoroughly. Inspect the interior of the tank to verify the amount of rust removed. If necessary, repeat the process until the desired level of cleanliness is achieved.
It is important to note that muriatic acid can be dangerous if not handled properly. Always wear protective gear and neutralize the acid with baking soda before disposal. Additionally, consider using alternative methods, such as vinegar or commercial rust removers, which are safer and less aggressive on the metal.
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Electrolysis using sodium carbonate
Electrolysis is an effective method for removing rust from the inside of a fuel tank. The process involves breaking down rust using electricity.
To remove rust from a fuel tank using electrolysis with sodium carbonate, you will need the following:
- A plastic storage container capable of holding eight or more gallons of water
- A bike or car battery and a battery charger
- Clamps
- A piece of steel round bar as a sacrificial anode
- A modified plastic spray paint can lid to keep the anode in position without touching the tank
- Hot water
- Sodium carbonate (also known as washing soda)
First, fill the plastic container with hot water and add about a cup of sodium carbonate per five gallons of water. Stir the solution until the sodium carbonate is fully dissolved.
Next, connect the positive and negative wires from the battery charger to the anode and the fuel tank, ensuring they are connected opposite to the plating process. Submerge the anode and the fuel tank in the solution, ensuring they do not touch each other.
Turn on the battery charger and let the electrolysis process run for at least 24 hours. The electricity will cause the rust to break down and be collected by the sacrificial anode.
After the process is complete, remove the fuel tank from the solution and rinse it thoroughly with water to remove any remaining rust or residue.
It is important to wear safety equipment when performing this procedure, such as eye protection and rubber gloves. Be sure to handle the sodium carbonate with care, avoiding contact with your skin, eyes, and inhaling it.
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Coating the tank with Red-Kote
Red-Kote is an internal fuel tank liner designed to seal leaks and prevent further rusting. It forms a tough, flexible membrane that will not crack or flake. It is also resistant to a range of additives, including ethyl alcohol, methyl alcohol, toluene, and isopropyl alcohol.
To coat the tank with Red-Kote, start by ensuring the tank is rust-free and dry. Place the tank on a stand that allows the can of Red-Kote to sit underneath the petcock opening. Plug any holes, such as the fuel sending unit, with rubber plugs, corks, or masking tape. Pour enough Red-Kote to coat the entire tank, then reinstall the gas cap. Rotate the tank to ensure even coverage. Most tanks require about half a quart of Red-Kote, but you can use more as you will drain the excess. Finally, remove the plug from the petcock mount and set the tank on the stand above the can of Red-Kote to allow the excess product to funnel back into the container.
Red-Kote usually requires about eight hours to dry. It is a long-term solution that will prevent rust from returning for many years.
Note that Red-Kote may narrow the holes for petcocks, so you may need to thin the coating using Acetone or MEK (methyl ethyl ketone).
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Frequently asked questions
Removing rust from inside a fuel tank can be done in several ways. One common method is to use a rust remover like Evaporust or strong vinegar, letting it soak for several hours or days, and then shaking the tank vigorously to remove any loose particles. Another method is to use electrolysis, which involves submerging the tank in a sodium carbonate solution and using an electric current to remove the rust. If the rust has caused holes or damage to the tank, it is recommended to replace the tank entirely.
There are several products that can be used to remove rust from a fuel tank. Evaporust is a popular product that many people have had success with. Other options include strong vinegar (30%), diluted muriatic acid, and sodium carbonate (often sold as a "pH increaser" for swimming pools). After using vinegar or acid, baking soda can be used to neutralize the solution.
After removing rust from a fuel tank, it is important to rinse the tank thoroughly with water and verify that all rust has been removed. You can then coat the inside of the tank with a product like Red-Kote to prevent rust from returning. Additionally, installing an inline fuel filter can help catch any rust particles that may remain.
