Mercedes Mullins
Rust in a diesel fuel tank can cause serious damage to your vehicle's performance and lead to costly repairs. It can clog filters, cause fuel injectors and carburetors to malfunction, and even render your engine unable to run. There are several methods to remove rust from a diesel fuel tank. One involves using a commercial rust remover, such as RustBlast, and following it up with a coating of Gold Standard Tank Sealer. Another method involves using distilled white vinegar, which contains acetic acid that dissolves rust. A third method involves using a degreaser, muriatic acid, and baking soda. After rust removal, it is important to coat the tank with a product like Red-Kote to prevent future rusting.
| Characteristics | Values |
|---|---|
| First Step | Empty the tank of any residual fuel and dry it out thoroughly. |
| Commercial Rust Removers | Evaporust, KBS Fuel Tank Sealer System, RustBlast, Gold Standard Tank Sealer, Red-Kote |
| Alternative Methods | Electrolysis, Chain Shake, Muriatic Acid, White Vinegar |
| Post-Cleaning | Neutralize acid with baking soda, flush with warm water, seal the cleaned surface |
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What You'll Learn
Using commercial rust removers
Commercial rust removers are a great option for removing rust from the inside of a diesel fuel tank. These products are designed to effectively remove rust without affecting the underlying metal or other materials. Some popular commercial rust removers include Evapo-Rust, KBS Coatings, and Krud Kutter. Here is a step-by-step guide on how to use these products:
Step 1: Empty and Inspect the Tank
Start by emptying the diesel fuel tank of any residual fuel and drying it thoroughly. You can do this by leaving the tank in the sun for a few hours. Once empty, use an LED torch to inspect the amount of rust inside the tank.
Step 2: Choose a Commercial Rust Remover
Select a commercial rust remover that is suitable for diesel fuel tanks. Evapo-Rust, for example, is effective on mild steel surfaces and will not affect PVC, plastic, rubber, or glass. KBS Coatings offer a similar product that is designed to remove rust and restore the inside of your tank.
Step 3: Apply the Rust Remover
Follow the instructions on the chosen product for the correct application method. For Evapo-Rust, pour enough of the solution into the tank to completely cover the rusty areas. Allow each side to soak for 2-3 hours, repeatedly turning the tank until each side has been treated. For KBS Coatings, their system includes KBS Klean, a powerful cleaner that removes soil and varnish. Dilute it with hot water, add metal objects like nuts and bolts as agitators, and shake the tank vigorously.
Step 4: Rinse and Neutralize
After removing the rust, rinse the tank with clean water to remove any remaining residue. If using an acidic product like muriatic acid, neutralize it with a base like baking soda and then flush the tank with warm water.
Step 5: Seal and Protect
Once the tank is clean and dry, apply a fuel tank sealer to protect the surface and prevent future rust. KBS Coatings offer a Gold Standard Tank Sealer that creates a tough, fuel-impervious coating. Pour it into the tank and roll the tank frequently to ensure it coats all interior surfaces.
By following these steps and using a commercial rust remover, you can effectively remove rust from the inside of a diesel fuel tank, restoring it to like-new condition and preventing future corrosion.
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Electrolysis with baking soda and water
Electrolysis is a method to remove rust without using chemicals. It involves using a positive electric charge (anodes) flowing through a sacrificial piece of steel to attract the rust, while the rust is simultaneously rejected through a negative electric charge (cathodes) flowing through the rusty item being cleaned while submerged in a solution of baking soda and water.
To remove rust from inside a diesel fuel tank using electrolysis with baking soda and water, follow these steps:
Step 1: Prepare the Electrolytic Solution
Fill a bucket with enough water to fill the fuel tank. For every gallon of water, add a tablespoon of washing soda (such as Arm & Hammer Super Washing Soda) and stir thoroughly. You can also use baking soda, or sodium carbonate, which is sold for swimming pools as "pH increaser". Adding more washing soda or baking soda won't speed up the process, but it doesn't seem to impede it either. Once the soda is dissolved, top off the tank with the solution. Put a cork in any holes at the bottom of the tank to avoid dripping.
Step 2: Prepare the Anode
The anode must not come into contact with the gas tank. It should be made of steel (not stainless) or iron. You can use a piece of steel rod held inside the tank with some scrap wood. The anode should be bent so that it doesn't slide into the tank or touch any parts inside.
Step 3: Connect the Battery Charger
Attach the negative lead from the battery charger to the tank and the positive lead to the anode. Turn on the charger and dial it to the 10-amp setting. Do not turn on the charger until all connections are made and the setup is complete.
Step 4: Start the Electrolysis Process
Step away from the setup and ensure you do not have any contact with the wires or the anode. Then, plug in and turn on the battery charger. You should see bubbles in the water as the current flows, creating electrolysis to remove the rust. Leave the setup to run for 8-10 hours at a time between check-ins.
Step 5: Rinse and Inspect the Tank
After electrolysis, rinse the tank with clean water and then inspect it thoroughly for any remaining rust or potential leaks. Use a flashlight to carefully examine the interior and don't rush this step. Any residual moisture can compromise the effectiveness of the sealant, so make sure the tank is completely dry before proceeding.
It's important to note that electrolysis is a time-consuming process and you won't start to see serious results for at least 24 hours, so patience is key. You may also need to use more than one round of the solution to safely remove all the rust.
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The chain shake method
To begin, you need to drain or transfer the diesel fuel out of the rusty tank. This is an important step as it ensures that the rust particles are not suspended in the fuel, making them easier to remove. Once the tank is empty, you can start the chain shake process.
It is recommended to shake the tank for an extended period, up to several minutes or even days, to ensure that as much rust as possible is removed. The longer and more vigorously you shake the tank, the better the results will be.
After shaking, carefully inspect the interior of the tank for any remaining rust or potential leaks. Use a flashlight to examine the surfaces thoroughly. This step is crucial to ensure that all the rust has been removed and to prevent future issues. Once you are satisfied that the tank is rust-free, it is important to ensure that the tank is completely dry before proceeding to seal it.
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Muriatic acid and baking soda
Muriatic acid is a weaker mixture of hydrochloric acid and is a potent substance that should be handled with care. It can be used to clean rust from a diesel fuel tank but must be neutralised with baking soda to prevent after-rusting.
To clean a diesel fuel tank with muriatic acid, first, inspect the tank to determine the severity of the corrosion. Drain the tank of fuel, disposing of it safely if it is old or rancid. If the tank has cracks or small holes, seal them with rubber or vinyl vacuum caps.
Next, pour the muriatic acid into the tank. The acid will loosen the rust, and an agitator, such as a handful of nuts and bolts, can help dislodge any remaining particles. The stronger the acid, the shorter the soaking period, with muriatic acid being able to complete the derusting process in as little as 15 minutes.
After removing the rust, the acid must be neutralised. Rinse the tank with a baking soda solution to neutralise any remaining acid residue and prevent damage to the metal inside. The baking soda will prevent the acid from continuing to work on the metal surface and causing after-rust. Drain the tank, rinse it with clean water, and then drain it again.
Finally, inspect the seals and replace them as needed. The tank is now ready to be reinstalled and refilled with fuel.
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Coating with Red-Kote
Coating the inside of a diesel fuel tank with Red-Kote is a long-term solution to prevent rust from returning. Before applying Red-Kote, the tank must be rust-free and dry. Begin by emptying the tank of any residual fuel and drying it out thoroughly. This can be done by simply leaving it in the sun for a few hours. Next, use a rust remover. Commercial rust removers are available; simply pour the product into the tank, seal it, and shake it vigorously. Let the remover sit for a while, as per the manufacturer's instructions, before draining it out. If the rust is stubborn, you can use a technique called electrolysis, which involves filling the tank with a liquid solution of baking soda and water and then using a battery charger to create an electrical current that dissolves the rust. Alternatively, a method called 'the chain shake' can be used, which involves placing a chain inside the tank and shaking it vigorously.
Once the tank is rust-free and dry, it's time to coat it with Red-Kote. Place the tank on a stand that allows the can of Red-Kote to sit underneath where the petcock was removed. Plug any holes with rubber plugs, corks, or masking tape. Pour enough Red-Kote to coat the entire tank, reinstall the gas cap, and rotate the tank to ensure even coverage. Most tanks require about half a quart of Red-Kote, but it's okay to use a little more as the excess product can be drained back into the container for later use. After coating, remove the plug from where the petcock would mount and set the tank on the stand above the can of Red-Kote to catch any excess product.
Red-Kote is a popular product for sealing and coating rusty fuel tanks due to its impressive adherence and longevity. It is important to note that rust in a fuel tank can cause serious issues, such as fuel contamination, clogged filters, and costly repairs. Therefore, addressing rust and properly coating the tank with a product like Red-Kote is crucial for the long-term health of the vehicle.
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Frequently asked questions
First, empty the tank of any residual fuel and dry it out thoroughly. Then, use a rust remover by pouring it into the tank, sealing it up, and shaking it vigorously. Let the remover sit for a while before draining it out. If there is still rust, repeat the process.
There are many commercial rust removers available. You can also use a product called RustBlast, or try distilled white vinegar. If the rust is stubborn, you can use a technique called electrolysis, which involves filling the tank with a liquid solution of baking soda and water and using a battery charger to create an electrical current that will dissolve the rust.
The chain shake method involves placing a chain into the diesel fuel tank and shaking it vigorously.
After removing the rust, you should coat the inside of the tank with a product like Red-Kote or Gold Standard Tank Sealer to prevent rust from returning.
