Sylvie Willis
Sealing a metal fuel tank is a process that can help extend the life of your fuel tank. It involves using a sealant to create an impervious barrier against rust, corrosion, and fuel leaks. There are various products available on the market, such as KBS Coatings' Auto Fuel Tank Sealer Kit, POR-15 Fuel Tank Sealer, and Eastwood's Gas Tank Sealer Kit, which provide the necessary materials for cleaning, rust removal, and sealing. The process typically involves cleaning the tank, removing rust, and coating the inside with a sealant. Some products, like the KBS Coatings' kit, offer a comprehensive solution, while others may require additional steps or treatments, such as using an acid wash or electrolysis for rust removal. The sealing process itself involves pouring the sealant into the tank and rotating the tank to ensure an even coating. This guide will explore the different options available and provide a step-by-step overview of the sealing process, helping you tackle this project with confidence.
Characteristics and Values of Sealing a Metal Fuel Tank
| Characteristics | Values |
|---|---|
| Reason for sealing | To prevent or repair rust, corrosion, and small fuel leaks |
| Prevention method | Keep the fuel tank full to avoid condensation and separate water from oxygen and metal |
| Sealant options | KBS Coatings Tank Sealer Kit, POR-15 Fuel Tank Sealer, Red Kote Tank Sealer, Epoxy, Eastwood Gas Tank Sealer Kit, Caswells Dragon Blood Kit |
| Preparation | Clean the tank, remove existing rust, degrease, treat with an acid metal etch or phosphoric acid, rinse, and dry |
| Sealing process | Pour in the sealant, rotate the tank to coat the entire inner surface, drain excess, and let it dry |
| Post-sealing care | Use fuel preservation and stabilizer to maintain the fuel system and prevent "stale gas" problems |
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Preventing rust
Rust is caused by water trapped inside the fuel tank. This can occur due to condensation, especially in environments with high humidity and rapid temperature changes. It can also happen when refuelling in the rain or snow, or when water pools at the bottom of the tank. To avoid rust in fuel tanks, you must separate the water and oxygen from the metal. One way to do this is to keep the fuel tank full, so the metal is not exposed to the air.
If you are concerned about rust, you can use epoxy to seal your tank. First, rinse the tank with water from a running garden hose to remove any fuel varnish. You can also use a wire brush and brake cleaner or denatured alcohol to clean the area. Next, remove valves, sending units, petcocks, and internal filters. Then, mix the entire contents of a metal wash with 2 gallons of hot water in a clean bucket. Pour the mixture into the tank and slosh it around, letting it sit for 5 minutes on each surface. Repeat this process until all the fuel varnish is removed, then pour out the contents.
To remove any remaining rust, you can use an acid treatment, such as phosphoric acid or muriatic acid. Make sure to follow proper handling instructions and work outdoors when using these products. After removing rust, rinse the tank thoroughly with water and let it dry. Once the tank is dry, you can apply a sealant, such as POR-15 Fuel Tank Sealer, Gold Standard Tank Sealer, or Red Kote Tank Sealer. These sealants create a barrier against rust, corrosion, and fuel leaks. Follow the instructions provided with your chosen sealant for proper application techniques.
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Cleaning the tank
Firstly, drain the tank and remove it from the vehicle. Then, wash the tank with hot, soapy water and thoroughly rinse it with water from a running garden hose. This step ensures that all the fuel varnish, residue, and gunk are removed from the tank. If there are stubborn areas of varnish, repeat the wash process until all traces are gone.
Next, to remove corrosion and rust, an acid treatment is required. Purchase Muriatic Acid from a hardware store and follow the safety instructions on the label. Do not add undiluted Muriatic Acid to the tank. Instead, dilute the acid and "slosh" it around on all internal surfaces. Continue this process until the surface of the tank has a uniform gray appearance, and there is no rust remaining.
After the acid treatment, rinse the tank thoroughly with water and let it dry completely. It is important to ensure that the tank is absolutely dry before proceeding to the next step, which is applying the sealant.
Some sources recommend using a product like POR-15 Metal Prep or KBS Coatings' RustBlast to prepare the metal for sealing. These products help to dissolve rust, coat the tank with zinc phosphate, and etch the metal for better adhesion of the sealer. Follow the manufacturer's instructions for these products, as they may vary.
Finally, inspect the tank to ensure that all rust has been removed and that the tank is completely clean. This step is crucial, as any remaining rust or contaminants can affect the adhesion and effectiveness of the sealant.
By following these steps, you will have a clean metal fuel tank that is ready for the sealing process.
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Removing rust
Firstly, it is important to assess the condition of the fuel tank. Drain a small amount of fuel and inspect it for rust particles or debris, which indicate severe rusting or corrosion inside the tank. If the tank is too damaged, de-rusting may not be sufficient, and replacement might be necessary.
If the tank is salvageable, start by draining the fuel. If the fuel is still usable, preserve it in a gas can or appropriate container. If the tank has cracks or holes, seal them with rubber or vinyl vacuum caps.
The next step is to choose a suitable rust removal method. Chemical cleaning typically involves using an acid to loosen the rust and an agitator to help dislodge particles. The safest acid to use is white vinegar (acetic acid), which is inexpensive, non-toxic, and unlikely to damage the metal. However, this process can take several hours or even overnight. More potent acids include phosphoric acid, muriatic acid, or oxalic acid, which work faster but require appropriate protective equipment due to stronger fumes and potential metal damage.
When using chemical cleaning, always work in a well-ventilated area due to the strong odours produced. Prepare a cleaning solution by mixing the chosen acid with water, following the recommended ratios for the specific acid used. Pour the solution into the tank until it is roughly half full. Then, introduce an agitator, such as steel BBs, nuts, bolts, or gravel, and shake the tank gently to ensure the solution reaches all interior surfaces. Let the solution sit and soak, allowing it to work on the rust.
After the soaking period, drain the cleaning solution from the tank and retrieve the agitators. Rinse the tank with a baking soda solution to neutralize any remaining acid residue and prevent metal damage. Finally, drain and rinse the tank with clean water to ensure all chemicals are removed.
For heavily rusted tanks, additional steps may be required. Some products, such as Evapo Rust, Metal Rescue, or CLR (Calcium, Lime & Rust Remover), can be left in the tank for several days to effectively remove stubborn rust. After using these products, remember to rinse the tank thoroughly and dry it completely before proceeding with sealing.
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Applying a sealant
To seal a metal fuel tank, you will need to apply a sealant. There are several products available for this purpose, including KBS Coatings' Gold Standard Tank Sealer, POR-15 Fuel Tank Sealer, and Eastwood Gas Tank Sealer. Here is a step-by-step guide on how to apply a sealant to your metal fuel tank:
Before applying any sealant, it is crucial to prepare the metal surface thoroughly. Start by cleaning the tank to remove any fuel residue, grease, or gunk. You can use a product like POR-15 Cleaner Degreaser or a mixture of hot, soapy water and a garden hose to rinse away the residue. Ensure that all valves, sending units, petcocks, and internal filters are removed. Next, neutralise any existing rust and etch the metal to improve the adhesion of the sealer. You can use products like RustBlast or phosphoric acid to achieve this. After applying the rust neutraliser, rinse the tank thoroughly with water and allow it to dry completely.
Once the tank is clean and dry, it's time to apply the sealant. For KBS Coatings' Gold Standard Tank Sealer, simply pour the entire can of sealer into the fuel tank. Slowly rotate the tank so that the inside surfaces are thoroughly and evenly coated. This step should take up to 30 minutes. Remember, the sealer should be applied in a single thin coat. Ensure that any remaining surface rust, leaky weld seams, and pinholes are sealed. Drain the excess sealer from the tank, being careful to avoid puddles as they can affect the adhesion.
If you are using POR-15 Fuel Tank Sealer, follow these steps: After cleaning and etching the tank, pour in the entire bottle of POR-15 Metal Prep to dissolve rust and coat the tank with zinc phosphate. Then, drain and rinse the tank with water, allowing it to dry completely. Once dry, pour in the entire can of Fuel Tank Sealer. Coat all surfaces and then drain the excess sealer after a few minutes.
For Eastwood Gas Tank Sealer, first, slosh acetone around the internal surfaces and then pour out the contents. Shake the sealer container well and pour the sealer into the tank. Temporarily close the fill neck and slowly rotate the tank in all directions to coat the entire inner surface. A properly coated tank should have a uniform bright white coating, and some excess sealer should remain. Let the tank stand for 8-10 minutes, then slowly rotate the tank again to allow the excess sealer to recoat all surfaces.
It is important to follow the specific instructions provided with your chosen sealant product and to take the necessary safety precautions during the application process. Always work in a well-ventilated area and wear protective gear, including heavy rubber gloves and eye protection.
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Draining the tank
Remove the Tank from the Vehicle:
First, carefully detach the fuel tank from the vehicle. This step provides access to the tank and allows for easier handling during the draining process. It is important to follow safety precautions and refer to the vehicle's manual or seek expert advice if needed.
Drain the Fuel:
Completely drain the fuel from the tank. This can be done by siphoning or pumping out the fuel into a safe and approved container. Ensure that you are wearing appropriate protective gear, such as gloves and eye protection, to avoid any fuel spills or contact with your skin or eyes. Follow local guidelines for disposing of or storing the drained fuel responsibly.
Rinse with Water:
After removing the fuel, thoroughly rinse the inside of the tank with water. Use a hose to flush out any remaining fuel residue, varnish, or debris. Rotate the tank during the rinsing process to ensure that all internal surfaces are reached. This step helps to remove any loose contaminants and prepares the tank for further cleaning and sealing.
Remove Valves and Internal Components:
To facilitate effective draining and cleaning, remove valves, sending units, petcocks, and internal filters. By doing so, you provide better access to the interior of the tank and ensure that all areas can be thoroughly cleaned and treated. Keep track of the removed components and their original positions for reassembly later.
Treat with Cleaning Solutions:
Depending on the condition of your tank and the severity of any corrosion or rust, you may need to use cleaning solutions or treatments. These can include metal wash, phosphoric acid, or muriatic acid. Always follow the instructions and safety precautions provided with these products. "Slosh" the cleaning solution around the internal surfaces of the tank, allowing it to work for the recommended amount of time. Then, pour out the contents and repeat if necessary until the tank is thoroughly cleaned.
Final Rinse and Drying:
After treating the tank with cleaning solutions, give it a final rinse with water to remove any residual chemicals. Ensure that all cleaning solutions are thoroughly rinsed away. Finally, allow the tank to dry completely before proceeding to the next step of the sealing process.
Remember, it is important to work in a well-ventilated area and follow safety guidelines when handling any chemicals or fuels. Take your time with each step to ensure that your metal fuel tank is properly drained and prepared for sealing.
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Frequently asked questions
To seal a metal fuel tank, you must first clean the tank, removing any existing rust and old sealers. Then, apply a coat of sealant to the inside of the tank. Finally, drain the tank to remove any excess sealant.
There are several products available for sealing a metal fuel tank, including:
- Gold Standard Tank Sealer
- POR-15 Fuel Tank Sealer
- Red Kote Tank Sealer
- Epoxy
- Eastwood Gas Tank Sealer
- Caswells Dragon Blood Kit
Before sealing a metal fuel tank, it is important to ensure that the tank is clean and dry. This can be achieved by washing the tank with hot, soapy water and thoroughly rinsing it with water. It is also recommended to remove any valves, sending units, petcocks, and internal filters.
Rust can be removed from a metal fuel tank using an acid treatment, such as phosphoric acid, muriatic acid, or RustBlast. The tank should be "sloshed" with the diluted acid and rotated to ensure that all internal surfaces are coated.
To prevent rust from forming in a metal fuel tank, it is important to keep the tank full of fuel. This will prevent water from condensing on the surfaces of the tank and combining with oxygen to create rust.
