Mercedes Mullins
Repairing an aluminium diesel fuel tank can be a challenging task, and often, it is more economical to replace the tank than to repair it. However, in some cases, repairing a fuel tank may be the only option. This may involve welding, especially for corroded tanks, but it is essential to ensure that the tank is free of any fuel and vapours before welding to avoid accidents. Additionally, the use of epoxy products has been suggested for repairing pitted aluminium diesel tanks, but results may vary. Proper installation and maintenance of aluminium tanks are crucial to prevent issues and ensure their longevity.
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What You'll Learn
- Welding: use argon to purge welds, remove liquid fuel, and displace vapour and oxygen
- Prevent corrosion: keep the tank dry and grounded, and use an epoxy primer
- Repair or replace: consider the cost of repair vs. replacement and the potential for future issues
- Product recommendations: JBWELD and POR 15 are two products used for aluminium tank repair
- Tank removal: consider the complexity of removing and reinstalling the tank
Welding: use argon to purge welds, remove liquid fuel, and displace vapour and oxygen
Welding an aluminium diesel fuel tank is a potentially dangerous endeavour due to the explosive nature of the fuel. It is important to take precautions to avoid any accidents.
Firstly, the tank should be drained of diesel. This can be done by using a wet/dry vacuum, but it is important to ensure that the vacuum is explosion-proof and has an exhaust vent to prevent any accidents. Alternatively, a small amount of isopropanol can be put into the tank and swilled around to mix with the remaining fuel, before being drained and vacuumed out. The tank should then be rinsed and dried. This can be done by blowing it out with compressed air or using a hot air gun.
Once the tank is empty and dry, the welding process can begin. Argon is the preferred gas for purging welds as it is inert, noble, and unreactive, ensuring that the base properties of the metal are not altered. It is important to slowly flood the hose with argon to avoid any mixing with oxygen, and the flow rate will depend on the hose size. A purge tool that matches the hose size should be used to minimise argon escape and oxygen penetration. The argon will displace the air in the tank, which can be purged out of a release hole at the top. Purging should continue for at least 30 seconds after welding is complete to prevent oxidation of the metal.
It is important to monitor oxygen levels during the welding process to ensure that the weld is not contaminated. This can be done using an oxygen sensor or a weld purging instrument. If oxygen levels rise too high, the welding operation should be shut down.
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Prevent corrosion: keep the tank dry and grounded, and use an epoxy primer
Keeping your aluminium diesel fuel tank dry and grounded is essential to prevent corrosion and ensure its longevity. Here are some detailed steps to achieve this:
Keep the Tank Dry:
Firstly, it is crucial to prevent moisture accumulation in and around your fuel tank. Ensure the tank bed is dry and well-ventilated. Use plywood as the base for the tank bed and treat it with epoxy to protect it from moisture. Install plastic strips on the bottom of the tank to elevate it slightly, allowing air circulation and preventing direct contact with moisture.
Keep the Tank Grounded:
Improper grounding of an aluminium fuel tank can lead to electrical issues and corrosion. To ground your tank properly, connect a ground wire to the fill connection. This will prevent electrical arcs when the fueling nozzle is inserted. Ensure the ground wire is securely attached to the metal deck fill fitting, running past the rubber fuel hose to the fuel tank itself. This will help dissipate any static electricity generated during fueling.
Use an Epoxy Primer:
Before applying an epoxy primer, thoroughly clean the tank by grinding, sanding, and washing it with acetone or an etch/alodine wash. Once the surface is prepared, apply a two-part epoxy primer, such as zinc chromate or strontium chromate. This primer will provide a protective layer that resists corrosion and strengthens the aluminium surface. You can further enhance protection by painting over the epoxy primer for added durability.
By following these steps, you can effectively prevent corrosion in your aluminium diesel fuel tank, ensuring its long-term reliability and safety.
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Repair or replace: consider the cost of repair vs. replacement and the potential for future issues
When deciding whether to repair or replace your aluminium diesel fuel tank, it is essential to consider the costs and potential future issues associated with each option. Repair costs for fuel tanks vary depending on the extent of the damage and the labour involved. In some cases, repairing a fuel tank may be dangerous and not advisable, especially if you are unsure about the procedure.
The cost of repairing a fuel tank can range from purchasing materials to fix the issue yourself to paying for labour costs at a repair facility. For example, if your diesel fuel tank has been contaminated with gasoline, you may need to pay for towing services and labour to drain and flush the tank, which can be expensive.
On the other hand, replacing a fuel tank can also be costly, with prices ranging from $400 to $2,500, depending on the vehicle's make and model. It is worth noting that replacing the fuel tank does not necessarily mean replacing the fuel pump simultaneously, which can save on costs. Additionally, if your fuel tank has been recalled by the manufacturer due to a fault, it may be repaired or replaced free of charge.
When deciding between repairing and replacing, it is essential to consider the potential for future issues. For example, if your aluminium fuel tank has corroded spots, repairing it may only be a temporary solution, and a replacement tank made from thicker metal may be a more durable option. Similarly, if your fuel tank is old and difficult to remove, replacing it may be more advisable to avoid potential safety hazards.
In conclusion, when deciding whether to repair or replace your aluminium diesel fuel tank, consider the cost of repairs versus replacement, the safety implications of each option, and the potential for future issues. While repairing may be cheaper in the short term, replacing the fuel tank may offer a more long-lasting solution and help prevent future problems.
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Product recommendations: JBWELD and POR 15 are two products used for aluminium tank repair
J-B Weld's TankWeld is a fuel and metal tank repair kit designed for permanent or temporary repairs of metal and fuel storage containers. The kit includes epoxy putty, fibreglass cloth, sandpaper, and an applicator. It is suitable for repairing leaks caused by cracks of up to 10 cm and holes up to 7 mm in diameter. JBWELD has been used by aluminium fuel tank owners for repairs, although some users have noted that it is only a temporary solution.
The POR-15 Fuel Tank Repair Kit is designed to prep, repair, clean, and seal automotive, farm, or industrial equipment fuel tanks. The kit includes a cleaner degreaser to remove gum, sludge, and varnish, Metal Prep to remove rust and prepare the tank for sealing, and Fuel Tank Sealer to create a permanent seal. This product has received positive reviews for its effectiveness in repairing and sealing fuel tanks.
Both the JBWELD and POR 15 kits are suitable for repairing aluminium fuel tanks. While JBWELD offers a quick and temporary solution, POR 15 provides a more comprehensive kit that includes cleaning and sealing products, making it a more permanent solution.
It is important to note that proper preparation of the tank is crucial for successful repairs. This includes removing any corrosion or moisture from the tank and ensuring that the tank is thoroughly cleaned and dried before applying any repair or sealing products.
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Tank removal: consider the complexity of removing and reinstalling the tank
Tank removal can be a complex process, and it is important to consider the challenges involved in both removing and reinstalling the tank. The first step is to carefully remove the fuel from the tank by syphoning it out and storing it in an approved container. This is a crucial safety measure, as releasing fuel under pressure can cause fires and injuries. It is also important to work in a well-ventilated area away from any sources of ignition, such as open flames, pilot lights, or incandescent light bulbs.
Once the fuel has been safely removed, the next step is to disconnect the hoses and electrical connectors. This includes supply lines, return lines, and vent hoses. It is important to be thorough and careful during this process, ensuring that all connections are properly disconnected. After the fuel lines and electrical connectors have been addressed, the metal straps holding the tank in place can be removed. However, before removing the tank, it is worth checking if there is an access panel that provides access to the fuel pump without the need for tank removal.
Reinstallation of the tank involves essentially reversing the removal process. The tank must be securely fastened with metal straps, and all hoses and electrical connectors must be properly connected and secured. It is important to exercise caution and attention to detail throughout the entire process, as any mistakes or oversights could lead to fuel leaks or other issues. Additionally, it is crucial to ensure that the tank is properly positioned and stabilized to avoid any damage or strain on the fuel lines and connections.
The complexity of tank removal and reinstallation can vary depending on the specific vehicle and tank configuration. In some cases, removing the tank may require additional steps, such as detaching it from the engine or other components. Therefore, it is essential to have a thorough understanding of the vehicle's layout and any unique considerations before attempting to remove or reinstall the tank. Furthermore, it is always recommended to consult a professional or seek advice from experienced individuals to ensure the procedure is carried out safely and effectively.
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Frequently asked questions
First, you need to drain the tank of diesel. Then, clean the aluminium and weld the crack or hole. You can also treat the tank with an epoxy primer for extra protection.
You can use a two-part epoxy primer on the tank, such as etch/alodine/strontium chromate, and then paint the tank for extra protection. You can also use JBWELD for repairs, but this is only temporary.
You should ensure that the tank bed is made of plywood and is epoxy-saturated and glassed over. You should also keep the area around the tank clean and grounded to prevent electrolisis.
If your tank has been badly damaged by electrolysis, it may be beyond repair. In this case, you may need to replace the tank with a plastic one. Additionally, if your tank is 15 years or older, it is recommended that you replace it rather than attempt a repair.
