Sylvie Willis
Sealing a fibreglass fuel tank is a messy and time-consuming job, but it can be done with the right tools and preparation. The first step is to drain the tank and let it dry completely. Next, sand the area around the leak or hole and clean it thoroughly with acetone, soap and water, and a cloth soaked in rubbing alcohol. It is important to be fussy about cleaning to ensure there is no fuel residue left in the tank. After cleaning, a two-part epoxy liner can be applied all around the perimeter of the opening, followed by a fibreglass patch. The epoxy liner from Caswell is a popular choice for sealing fibreglass fuel tanks and has received good reviews. However, it is important to note that the tank must be thoroughly cleaned and coated to prevent fuel from leaking through the liner. Other products such as RedKote, ReKote, and Kreem are also available for sealing fuel tanks, each with its own advantages and disadvantages.
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What You'll Learn
Sanding and cleaning the tank
Start by draining the tank completely. This step is essential as it ensures that no liquid remains in the tank, allowing for a more thorough cleaning process. Once drained, allow the tank to air dry for several days. The drying time may vary depending on the temperature and humidity of your location, so it is important to be patient and ensure that the tank is completely dry before proceeding.
The next step is to sand the tank. Use coarse-grit sandpaper to roughen the surface around the hole or crack that needs to be repaired. This process creates a textured surface that will help the adhesive compound adhere properly. Make sure to sand in a circular motion, applying even pressure to achieve a consistent finish. Collect any dust or debris created during the sanding process and remove it from the tank to avoid contamination.
After sanding, it's time to clean the tank thoroughly. Start by using a cleaning agent such as acetone or phosphoric acid tank cleaner to remove any grease, oil, or fuel residue. These cleaning agents can cut through tough grime and ensure that the tank's surface is free of any contaminants. Follow the instructions on your chosen cleaner and wear appropriate protective gear during this process.
Once the tank is cleaned with acetone or a similar solvent, it is essential to rinse and clean it again with soap and water. This step ensures that any chemical residue from the previous cleaning step is removed and that the tank is left thoroughly cleaned. After rinsing, dry the tank completely. You can use a hairdryer to speed up the drying process, ensuring that all moisture is eliminated.
Finally, it is crucial to allow the tank to "'breathe" after cleaning and drying. Leave the tank open for about a week, turning it slowly in different directions (up, down, side to side, front to back) during this period. This step ensures that any residual fumes or odours dissipate, creating a fresh surface for the sealant application.
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Applying an epoxy glue
Preparation:
Before applying the epoxy glue, it is crucial to thoroughly clean the fibreglass fuel tank. Use acetone to clean the tank, followed by soap and water. Ensure that there is no fuel residue left in the tank, as it can get trapped between the new coating and the paint, leading to potential issues. Rinse and dry the tank completely, using a hairdryer if needed. Leave the tank open for about a week to allow it to "breathe." During this time, keep turning the tank slowly in all directions to ensure all areas are dry.
Applying Epoxy Glue:
- Wear protective gloves throughout the process to safeguard against chemical exposure, as gasoline can cause severe skin irritation.
- Use petroleum jelly (Vaseline) to apply a 12-inch perimeter around the area where you will be working. This will ensure a smooth transition when applying the epoxy glue.
- If there are any screws or bolts in the way, remove them before applying the epoxy. The adhesive needs access to bond with the fibreglass and the metal surface.
- Apply the epoxy glue generously over the area that needs to be sealed. Work the epoxy into the fibreglass, ensuring that it penetrates the material.
- Use a heat gun during the drying process to smooth out any bumps and create a nice flat surface. Be careful not to burn yourself.
- Allow the epoxy glue to dry completely before considering using the vehicle.
Post-Application:
After applying the epoxy glue, it is important to allow it to cure completely. The epoxy may generate a little heat during the curing process, which is normal. You can test the seal by filling the tank with gasoline and checking for any leaks. If properly applied, the epoxy glue should provide a strong and durable seal, preventing fuel leaks and ensuring the tank's integrity.
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Using a fiberglass patch
Sealing a fibreglass fuel tank with a fibreglass patch is a straightforward process, but it requires careful preparation and safety precautions. Here is a step-by-step guide:
Prepare the Tank
Start by removing the plastic gas tank from the vehicle and setting it up in a secure workspace. Drain the gasoline from the tank and allow it to dry completely, both inside and out. This step is crucial to ensure that the adhesive compound will adhere properly.
Sand and Clean
Once the tank is dry, don safety gear, including protective eye protection. Begin sanding the area around the hole or crack with coarse-grit sandpaper. This step will roughen the surface, allowing the adhesive to grip better. After sanding, use a shop cloth saturated with rubbing alcohol to clean the area thoroughly.
Apply Epoxy
Mix the two-part epoxy according to the manufacturer's instructions. Apply the epoxy mixture generously around the perimeter of the opening, making sure to cover at least 12 inches at a time. You can use a putty knife or similar tool to smooth out the epoxy and ensure an even application.
Apply the Fibreglass Patch
Cut a fibreglass patch to size, ensuring it is large enough to cover the opening with some overlap. Place the patch over the hole, pressing it firmly into the epoxy. Smooth out any bumps or creases, and apply pressure to ensure good contact and adhesion.
Let it Dry and Sand
Allow the epoxy to dry completely. The drying time will vary depending on the product used and environmental conditions. Once dry, use fine-grit sandpaper to sand the patched area, smoothing out any remaining bumps or unevenness. Remove any sanding dust with a tack cloth or a damp cloth.
Paint (Optional)
If desired, you can spray paint the patched area with plastic paint to improve the aesthetic appearance of the repair. Allow the paint to dry, and you're done!
Remember, always work in a well-ventilated area and wear protective gear, including gloves and eye protection, when handling chemicals and sanding.
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Sealing with a liner
Sealing a fibreglass fuel tank with a liner involves a few key steps and considerations. Firstly, it is essential to prepare the tank thoroughly by cleaning and rinsing it multiple times to ensure no fuel residue remains. This step is crucial as any fuel residue can get trapped between the new coating and paint, compromising the effectiveness of the liner. The tank should be cleaned with acetone, soap and water, and then left to dry.
Next, the choice of liner is important. There are several products on the market, including Caswell epoxy, Kreem, Hirsch, POR-15 Fuel Tank Sealer, Flowliner Armour Coat, KBS Tank Sealer, and Gold Standard Tank Sealer. Each product has its own advantages and disadvantages, so it is important to choose one that suits your specific needs. For example, Caswell epoxy has a good reputation and adheres well to fibreglass, but it generates a little heat during curing. Kreem and Hirsch are also popular options, with Kreem having a more rubbery finish and Hirsch drying to a smooth, shiny finish that adheres well to fibreglass.
Once the liner product has been chosen, it is important to follow the manufacturer's instructions carefully. For example, the Caswell epoxy requires shaking screws inside the tank, cleaning the tank with acetone, and then coating the tank. It is also important to ensure that all surfaces of the tank are coated, as any uncoated areas can lead to leaks. After coating, the tank should be drained to remove any excess sealer.
Finally, once the liner has been applied, it is important to maintain the fuel system properly. This includes using fuel preservation and stabilizer to keep the system in proper working order and to avoid "stale gas" problems. It is also recommended to keep the tank open to 'breathe' for a period after sealing, and to regularly turn the tank slowly in all directions.
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Drying and painting
Cleaning and Preparation
Before beginning the sealing process, it is essential to thoroughly clean the fuel tank to ensure there is no fuel residue left behind. This step is crucial as any remaining fuel can migrate between the new coating and the paint, causing potential issues. Clean the tank multiple times with acetone, soap, and water, and allow it to dry completely. Use a hairdryer to speed up the drying process, and leave the tank open in a warm area for about a week to allow it to "breathe." During this time, keep turning the tank slowly in all directions to ensure proper ventilation.
Sealant Application
Once the tank is thoroughly cleaned and dried, it's time to apply the sealant. There are various products available, such as Caswell epoxy, Kreem, Hirsch, RedKote, and ReKote. Each product has its own advantages, so choose one that suits your needs. Before applying the sealant, shake screws inside the tank to ensure proper mixing. It is crucial to follow the manufacturer's instructions for the specific sealant you choose, as each product may have unique application requirements.
Painting
After the sealant has dried completely, you can begin the painting process. Start by sanding or grinding the surface to create a rough finish, which will help the paint adhere better. Use a vibrating electric hand sander or an air grinder with 80-grit sandpaper for this step. Ensure you wear proper safety equipment, including a respirator, to protect yourself from dust and debris. After sanding, wipe down the tank with a solvent such as lacquer thinner or acetone to remove any residue. Once the tank is prepared, apply a thin coat of paint mixed with resin to the portions of the fuel tank that will be covered with cloth. Allow this first coat to dry completely before proceeding. The drying time will vary depending on temperature and ventilation, so adjust accordingly.
Final Coats and Curing
After the first coat has dried, apply a heavy coat of mixed resin and immediately cover it with the cloth, working out any air bubbles and ensuring the cloth lays flat. Completely saturate the cloth with more resin, using your fingers to work it down into the cloth. Allow this second coat to dry, and then apply additional coats as needed to achieve a smooth and even finish. Remember to follow the specific instructions for the products you are using, as curing times may vary. During the curing process, ensure that the tank does not come into contact with any surfaces, as this can affect the curing process.
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Frequently asked questions
There are several sealants available for fibreglass fuel tanks, including Caswell, RedKote, ReKote, Kreem, and Hirsch. Caswell epoxy is a popular choice, generating a little heat during curing and drying to a gasoline-resistant finish. However, it is important to thoroughly clean and coat the entire tank to ensure the sealant adheres properly.
The preparation process for sealing a fibreglass fuel tank can be time-consuming. First, drain the tank and allow it to dry completely. Next, clean the tank with acetone, followed by soap and water. Then, use a hairdryer to ensure the tank is completely dry. Leave the tank open in a warm place for about a week, turning it slowly in different directions to expose all surfaces to the air.
To seal a fibreglass fuel tank with epoxy, start by draining the tank and sanding the area around any holes or cracks. Clean the area with a cloth soaked in rubbing alcohol. Mix the epoxy and apply it around the perimeter of the opening. Cut a fibreglass patch to cover the opening with overlap. Place the patch over the hole, pressing it into the epoxy. Allow the epoxy to dry, then smooth out any bumps with sandpaper. You can also spray paint the area with plastic paint if desired.
