Sylvie Willis
Repairing a poly fuel tank can be a challenging task due to the nature of the materials involved. Polyethylene (PE) plastic, commonly used in fuel tanks, is known for its excellent chemical resistance, making it challenging for adhesives to bond effectively. While some sources advise against repairing and suggest opting for a replacement tank instead, there are several methods that individuals have employed to address leaks and cracks in poly fuel tanks. These methods include using sealants or adhesives, mechanical patches, welding, and specialised repair systems like Tech-Bond. This paragraph introduces the topic of repairing a poly fuel tank, acknowledging the challenges and highlighting the various approaches individuals have explored to address leaks and cracks in these tanks.
Repairing a Poly Fuel Tank
| Characteristics | Values |
|---|---|
| Materials | HDPE plastic, Polyethylene, Permatex 2, Tech-Bond adhesives, Green Adhesive, Blue Adhesive, Black Adhesive, Fiberglass, Epoxy, G Flex, Polyurethane |
| Tools | Sandpaper, Soldering iron, Grinder, Course disc, Torch |
| Techniques | Sanding, Soldering, Welding, Gluing, Flame the surface, Patching |
| Considerations | Safety, Cost, Adhesion, Bonding, Durability, Replacement availability |
| Challenges | Gasoline, Solvents, Oils, Water, Pressure, UV damage |
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What You'll Learn
Using a sealant or adhesive
If you do wish to proceed with a repair using a sealant or adhesive, there are several methods you can try. Firstly, ensure that you have drained the tank and cleaned it inside and out with soapy water. Next, sand the area around the leak or hole to create a rough surface that will allow the adhesive to adhere properly.
One method is to use a soldering iron or electric soldering gun to melt a plastic patch over the hole or crack. Cut a plastic patch from a similar material to the fuel tank, slightly larger than the damaged area. Heat the edge of the crack with the soldering iron or gun, creating a trench, then lay the patch over the area and smooth it with the heat. This method can also be done using strips of a milk jug instead of a plastic patch.
Another method is to use a two-part epoxy glue. Cover the patch with the glue and allow it to set, then sand and spray with plastic paint if desired. However, it is important to note that epoxy glue dries rigid, and poly fuel tanks expand and contract with temperature changes, so this method may fail after a short time.
Other adhesives mentioned as possible solutions include Permatex 2, JB weld, Loctite PL S-40, G-Flex, and PRC B1/2. When using any adhesive, always ensure that it is suitable for use with the type of plastic in your fuel tank and that it is fuel-resistant.
Additionally, one source suggests using a sheet metal and sealant combination to create a temporary repair. However, this is not a permanent solution, and replacement is still recommended.
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Sanding the surface
When sanding, it is essential to use the appropriate type of sandpaper. Medium-rough sandpaper is generally recommended for this task. Start by emptying the fuel tank and ensuring that it is thoroughly dry. This is crucial, as fuel or moisture can interfere with the repair process and affect the final result. Once the tank is dry, use the sandpaper to sand around the problematic area. Be thorough and ensure that the entire area is evenly sanded.
The sanding process will generate debris and dust. After sanding, it is important to clean the surface again to remove any remaining dust or debris. This can be done with a clean, dry cloth or a brush. A tack cloth is also useful for this purpose, as it can effectively pick up any remaining dust particles, ensuring a clean surface for the next steps of the repair.
In some cases, it may be necessary to repeat the sanding process a second time, especially if the first round of sanding did not result in a sufficiently rough surface. After the final sanding, it is usually recommended to once again clean the surface with a solvent, such as acetone, to ensure that the repair material will adhere properly. This step should be done with caution, as using the wrong solvent can damage the plastic.
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Applying heat
To repair a poly fuel tank with heat, you will need to use a soldering iron or a welding kit.
First, empty the tank of fuel and leave it open to prevent pressure from building up inside. Next, use medium-rough sandpaper to sand the area around the crack. Sanding will clean the area and allow the plastic to bond better. It will also help fill the crack.
When using a soldering iron, set the temperature between 250-300 degrees Celsius. A wider soldering tip, around 1cm wide, will help dissipate the heat evenly around the crack. Heat the surrounding area, not just the crack, so that the plastic stick will bond better to the tank. Take a plastic stick in one hand and the soldering iron in the other. Apply heat to the tank, then remove the soldering iron, place the stick on the tank, and apply heat to the stick. You will feel the plastic melt and bond.
Alternatively, you can use plastic welding to repair the tank. This involves softening the plastic with heat and uniting the surfaces. You can use a propane torch to hold near the area to return the glossy sheen to your tank.
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Plastic welding
To begin the plastic welding process, the fuel tank must be emptied and left open to release pressure. The area around the crack should then be sanded with medium-rough sandpaper to clean the surface and allow for better bonding. A soldering iron is then used to apply heat to the crack, with a temperature between 250-300 degrees Celsius.
The plastic rod, which can be created from an HDPE plastic bottle, is melted into the crack, filling it with the same type of plastic as the original tank. This process is repeated along the length of the crack, ensuring that the plastic is properly bonded. Once the crack is filled, the area is sanded again to smooth out any uneven surfaces.
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Replacement options
If you're looking to replace your poly fuel tank, there are several options available to you. Firstly, you could opt for a polyethylene tank, which offers superior strength and durability compared to metal tanks. Polyethylene tanks are also lighter, corrosion-resistant, and have no welds or seams that could fail or break. This makes them a long-lasting option.
Another option is to go with a mild steel tank. Mild steel has a higher galvanic rating than aluminum, making it a durable choice—some mild steel tanks have lasted 30 to 50+ years. However, keep in mind that mild steel tanks may be more challenging to install and maintain than aluminum ones.
Aluminum tanks are also an option for replacement. Aluminum has the advantage of being lighter and easier to weld than mild steel. However, as mentioned in the previous paragraph, it has a lower galvanic rating, which may be a consideration for long-term use.
Other materials you could consider include stainless steel, fiberglass, and even plastic welding for a quick fix. When choosing a replacement tank, it's essential to consider factors such as durability, ease of installation, and maintenance to ensure the best option for your specific needs.
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Frequently asked questions
Sealants and adhesives do not work well with poly fuel tanks. One product that does stick to poly is Permatex 2, but it only works as a sealant, not an adhesive.
The best way to repair a poly fuel tank is by welding.
First, empty the tank of fuel and leave it open to prevent pressure from building up. Next, sand the problematic area to clean it and allow the plastic stick to bond better. Then, take a plastic stick and a soldering iron, and apply heat to the crack, melting the plastic stick so that it bonds to the tank.
Some alternatives to welding include using a flanged fitting or a mechanical patch. However, these methods may not be legitimate repairs and may not be safe, especially if the tank has held gasoline.
