Katerina Swanson
Rust in diesel fuel tanks can cause havoc, including clogged fuel filters and drivability issues. To seal a diesel fuel tank, you must first clean the tank, removing existing rust, gum, varnish, and flaky rust. Then, you need to prepare the metal to receive the sealant by using an acid metal etch or phosphoric acid cleaner. After that, you can apply the sealant by pouring it into the tank and rotating the tank to ensure all the interior surfaces are coated. Finally, drain the excess sealant and let the tank dry for at least 24 hours before refilling with fuel. There are various products available for sealing diesel fuel tanks, including POR-15 Fuel Tank Sealer, Gold Standard Tank Sealer, and Rustbuster Fuel Tank Seal Slosh. Some people also recommend using epoxy or electrolysis to seal fuel tanks.
Sealing a diesel fuel tank
| Characteristics | Values |
|---|---|
| Why seal a diesel fuel tank | To prevent or fix rust, corrosion, and small fuel leaks |
| When to seal a diesel fuel tank | When there are signs of rust or corrosion, or as a preventative measure if the tank has had issues with rust in the past |
| How to seal a diesel fuel tank | Clean the tank, remove existing rust, and coat the inside of the tank with a sealant |
| Products used to seal a diesel fuel tank | POR-15 Fuel Tank Sealer, Red Kote Tank Sealer, Gold Standard Tank Sealer, ProSeal, Flamemaster, Caswells Dragon Blood kit, Rustbuster Fuel Tank Seal Slosh, Epoxy fiberglass resin |
| Tips for sealing a diesel fuel tank | Ensure the tank is thoroughly cleaned and dried before applying sealant, follow the directions for the specific product, wear gloves and protective clothing to avoid contact with skin |
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What You'll Learn
Removing rust
Rust in fuel tanks can cause all sorts of problems, from clogged fuel filters to fuel leaks. The first step in sealing a diesel fuel tank is to remove any existing rust.
To start, drain the tank and remove any built-up gum or varnish, as well as loose, flaky rust. This can be done using a variety of tools and materials, including an aluminium straight edge scraper, fuel absorbent pads, sandpaper, Scotchbrite pads, acetone, and a shop vac. It is important to clean the tank thoroughly and ensure it is free from contamination before applying any sealants.
Once the tank is clean, the next step is to neutralise any remaining rust and prepare the metal to receive the sealant. This can be done using an acid treatment, such as phosphoric acid or RustBlast, which will etch the metal and leave a zinc phosphate coating. The tank should be rotated regularly during this process to ensure that all the inside surfaces are coated.
After the acid treatment, the tank should be rinsed thoroughly with water and allowed to dry completely. This is an important step, as any remaining moisture can cause the sealant to foam and bubble, affecting its ability to adhere to the metal.
Once the tank is completely dry, the rust removal process is complete, and you can move on to sealing the tank.
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$64.98
Using an acid treatment
Sealing a diesel fuel tank with an acid treatment involves using a substance called muriatic acid, which is a mixture of hydrochloric acid. Muriatic acid is a potent substance that can effectively clean and remove rust from the tank. However, it requires careful handling due to its corrosive and hazardous nature. Here is a step-by-step guide on using an acid treatment to seal a diesel fuel tank:
Step 1: Ventilation and Protection
Before starting the process, ensure you are working in a well-ventilated area to avoid inhaling harmful fumes. Put on protective gear, including gloves, eye protection, and clothing that covers your skin to avoid any contact with the acid.
Step 2: Prepare the Acid Solution
Muriatic acid needs to be diluted before use. Prepare a solution by mixing the acid with hot water, ensuring the temperature remains warm throughout the process. You can also add a handful of nuts and bolts to the solution, which will aid in removing stubborn residue.
Step 3: Apply the Acid Treatment
Pour the diluted acid solution into the diesel fuel tank. Shake and rotate the tank to ensure the acid comes into contact with all interior surfaces. Let it sit for a few minutes to allow the acid to dissolve any rust and varnish.
Step 4: Rinse and Inhibit Rust
After the acid treatment, thoroughly rinse the tank with water to remove any remaining acid, chlorides, and residue. Pay attention to remote areas of the tank to ensure a comprehensive rinse. To prevent subsequent oxidation (rust), apply a rust inhibitor to the freshly cleaned steel surfaces.
Step 5: Seal the Tank
Once the tank is clean and treated with a rust inhibitor, it is crucial to seal the tank promptly to prevent rust formation. You can use a tank sealer kit, such as the KBS Tank Sealer Kit or similar products, to coat the inside of the tank and create a protective barrier. Follow the instructions provided with the kit for the best results.
It is important to note that using muriatic acid for cleaning fuel tanks is controversial due to its hazardous nature and the potential for subsequent rusting if not properly inhibited. Some users recommend alternative methods like abrasive blasting or electrolysis for removing rust and sealing the tank. Always exercise caution and consider seeking professional help if you are unsure about the process or have a severely damaged tank.
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Applying a sealant
Sealing a diesel fuel tank involves a few steps, with the sealant application being the most crucial. Before applying the sealant, the tank must be cleaned and prepared. This includes removing any built-up residue, varnish, or loose rust, and ensuring the tank is dry. Some sources recommend using an acid treatment, such as phosphoric acid, or products like POR-15 Cleaner Degreaser, to clean the tank and neutralize existing rust. It is important to follow the instructions provided with your chosen sealant product for the best results.
Once the tank is clean and dry, it's time to apply the sealant. The application process may vary slightly depending on the sealant product and the size of your tank, but the basic principles remain the same. Most sealants require the entire can or bottle of sealant to be poured into the tank. The tank is then slowly rotated and moved in all directions to ensure the sealant thoroughly and evenly coats the entire interior surface. This step may need to be repeated after a few minutes to ensure complete coverage.
It is important to follow the manufacturer's instructions for how long to leave the sealant in the tank before draining the excess. Some products recommend draining after about 10 minutes or up to 30 minutes of rotation, while others suggest leaving the sealant in the tank for up to an hour to ensure all surfaces are coated. Excess sealant should be thoroughly drained from the tank to prevent puddles, as these can affect the sealant's ability to adhere and may cause foaming or bubbling.
After draining, the tank should be left to air dry in a well-ventilated area. The curing time can vary depending on the product, with some recommending 24 hours, 96 hours for maximum cure, or even up to a week to ensure the sealant is smooth and hard.
It is important to note that some sealants, like POR-15, can be very sticky and difficult to remove from the skin, so it is crucial to wear gloves and protective gear during the application process. Additionally, some products may require the tank to be free of plastic parts or contamination before applying the sealant. Always read and follow the instructions provided with your chosen sealant for the best results.
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Drying the tank
Firstly, it is important to thoroughly clean the tank to remove any built-up residue, gum, varnish, or loose rust. This can be done using a degreaser, such as POR-15 Cleaner Degreaser, or a caustic detergent like Rustbuster Tank-Kleen, along with a power wash or a scraper, fuel absorbent pads, sandpaper, and other tools as needed.
Once the tank is clean, the next step is to neutralize any remaining rust and prepare the metal surface to receive the sealant. This can be done using an acid metal etch product like RustBlast or phosphoric acid, which will also leave a zinc phosphate coating to enhance the adhesion of the sealant. The product should be poured into the dry tank, and the tank should be rotated regularly for at least 30 minutes to ensure that the entire interior surface is coated.
After the acid treatment, it is crucial to rinse the tank thoroughly with water to remove any residue or chemicals. This step ensures that the tank is clean and free of any contaminants before proceeding to the drying stage.
The tank should then be drained of all water and left to air dry completely. It is recommended to allow the tank to dry for several days to ensure that all moisture is evaporated. This step is crucial, as any remaining moisture can affect the adhesion of the sealant and may lead to future rust issues.
In some cases, it may be beneficial to perform an additional treatment to ensure the tank is completely dry. This could involve using a product like acetone to rinse the tank after the initial drying period. Additionally, ensuring proper ventilation during the drying process can help accelerate evaporation and prevent moisture buildup.
By following these steps and allowing ample time for drying, you can ensure that your diesel fuel tank is adequately prepared for the sealing process, reducing the risk of future rust and corrosion issues.
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Preventing future rust
Rust in fuel tanks can create all sorts of problems, from clogged fuel filters to fuel leaks. Rust is caused by condensation—that is, moisture in the air condenses on the inside of the tank. To prevent future rust, it is important to seal your diesel fuel tank.
There are two ways to fix a rusty fuel tank: replace the tank with a new one or seal the rusty fuel tank. The latter is a cheaper option, although it may be harder for larger tanks and may require two people to distribute the sealant. The procedure to seal a rusty fuel tank is to clean the tank, remove existing rust, and coat the inside of the tank with a sealant.
To clean the tank, you can use a product such as KBS Klean or Rustbuster Tank-Kleen caustic detergent and a power wash. You can also use an acid treatment, such as phosphoric acid tank cleaner, or treat the tank with Ospho. After cleaning, the tank should be free of contamination and structurally sound.
To remove rust, you can use an acid metal etch like RustBlast, which neutralizes existing rust, etches the metal, and leaves a zinc phosphate coating so that the tank sealer can adhere better. The tank should then be rinsed thoroughly with water and allowed to dry.
Once the tank is clean and dry, you can apply the sealant. There are various sealants available, such as POR-15 Fuel Tank Sealer, Gold Standard Tank Sealer, Red Kote Tank Sealer, and KBS Coatings Tank Sealer Kits. The sealant should be poured into the tank and the tank slowly rotated so that the inside is thoroughly and evenly coated. It is important to take the time to coat the entire tank well and ensure that any remaining surface rust, leaky weld seams, and pinholes are sealed.
After sealing, the tank should be allowed to air dry in a well-ventilated area. The curing time will vary depending on the product used, but it can range from 24 hours to 96 hours for maximum cure.
By following these steps and regularly maintaining your diesel fuel tank, you can help prevent future rust and keep your fuel system in proper working order.
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Frequently asked questions
Rustbuster Fuel Tank Seal Slosh is a product that can be used to seal diesel fuel tanks. It is designed for the sealing of fuel petrol and diesel tanks and has been tested with dilutions of up to 85% Corn Bioethanol without any breakdown of the coating.
To seal a rusty diesel fuel tank, you must first clean the tank, remove existing rust, and coat the inside of the tank with a sealant. There are various products available for this purpose, including the POR-15 Fuel Tank Sealer, KBS Coatings, and Gold Standard Tank Sealer.
Some products that can be used to seal a diesel fuel tank include POR-15 Fuel Tank Sealer, Red Kote Tank Sealer, Gold Standard Tank Sealer, KBS Coatings, and ProSeal.
