Ameer Randolph
A rusty fuel tank can be a headache, but it's not an uncommon problem. Rust in the fuel tank can cause costly repairs if left untreated, as it can travel and create hazards for your carburetors, petcock, and fuel pump. There are several methods to treat a rusty fuel tank, including using chemical treatments, abrasive materials, or electrolysis. The best method depends on the extent of the rust and the condition of the tank. If the tank has holes or is severely damaged, it may be more cost-effective to simply replace it. However, if the tank is irreplaceable or unique, restoration may be the only option. This can be done using chemical treatments like Red-Kote, Evaporust, or CLR (Calcium, Lime & Rust Remover), or by using electrolysis with a bike or car battery and sodium carbonate.
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What You'll Learn
When to treat a rusty fuel tank
If the structural integrity of the tank is uncompromised, there are several methods to treat a rusty fuel tank. One method is to use electrolysis or electrolytic cleaning, which involves using an electric current in an electrolytic bath to remove rust from metal surfaces. This method requires a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate. Another method is to use chemical treatments, such as CLR (Calcium, Lime & Rust Remover) or Evaporust, to remove the rust. Additionally, abrasive materials with small mineral particles can be used to scour off rust from surfaces.
It is important to act promptly when treating a rusty fuel tank to prevent further damage and ensure the safety of the vehicle.
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How to treat light surface rust
To treat light surface rust on a fuel tank, you should first remove the tank and drain it of fuel. You can do this by locating the fuel line connecting the gas tank to the fuel injectors or carburetor and placing a container underneath to catch the fuel. Loosen the fuel line clamps with pliers and pull them off. If your bike has a petcock, set it to OFF and then back to ON to let the fuel out of the tank.
Next, you'll want to fill the tank with a cleaning solution. A mild acid like white vinegar is a good option for treating light surface rust as it is readily available, affordable, and effective at dissolving rust. Fill the tank halfway with vinegar and shake gently to ensure the vinegar reaches all interior surfaces. Let the vinegar sit for several hours or overnight.
After letting the vinegar sit, drain the cleaning solution from the tank by tipping it upside down and shaking out any remaining liquid. Rinse the tank with a baking soda solution to neutralize any remaining acid residue and prevent damage to the metal. Drain and rinse the tank with clean water, then drain it again.
Once the tank is thoroughly cleaned and dried, inspect the seals and replace them as needed. You can then reinstall the tank and refill it with gas.
To prevent rust from forming again, consider using a motor treatment product like Sea Foam every 2,000 to 5,000 miles. You can also apply a clear rust inhibitor spray to the outside of the tank.
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How to treat heavy rust
If the structural integrity of your fuel tank is compromised due to heavy rust, you may need to cut it open for further inspection and repair. However, if the tank is only mildly rusted, you can attempt to treat the rust yourself.
First, drain the tank of any remaining fuel. Then, wash the tank with a degreaser and rinse it out. Seal all openings except for the fuel filler, and pour in enough muriatic acid to coat the inside of the tank. Tip and roll the tank to ensure that the acid reaches all areas. Check the progress through the filler and add more acid if necessary. Once you are satisfied with the results, neutralise the acid with a base like baking soda and flush the tank with warm water.
If you are unable to dip the tank into a hot tank, you can use a chemical product like Evapo-Rust instead. Fill a container with enough Evapo-Rust to completely cover the tank. Give the tank a quick clean with a brush and degreaser to speed up the process. Place the tank in the solution and leave it to soak. Heavy rust may require an overnight soak. Once the rust is removed, rinse the tank under clean water and apply a rust-proof coating to prevent future corrosion.
Alternatively, you can fill the tank with a rust treatment like white vinegar or caustic soda solution, along with some small nuts, bolts, or stones. Seal the tank and shake it vigorously for several minutes. Empty the tank and repeat the process if necessary.
After removing the rust, you should install an inline fuel filter to catch any remaining rust particles and prevent them from damaging your engine. To prevent rust from forming again, use a motor treatment product like Sea Foam every 2,000 to 5,000 miles.
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How to prevent rust from returning
To prevent rust from returning, it is important to first assess the extent of the rust. Look for pinholes or spots in the tank where the rust has made the tank wall too thin. If there are numerous or large holes, the only option is to cut out the damaged parts and weld new metal patches. This process will also require repainting.
After treating the rust, the next step is to coat the inside of the tank with a product like Red-Kote, which has been praised for its adherence and longevity. This will prevent rust from returning for many years. It is important to follow the manufacturer's instructions when applying the coating.
Another way to prevent rust from returning is to install an inline fuel filter between the tank and the fuel pump. The filter will catch any rust particles left behind. Additionally, using a product like Fogging Oil can help prevent rust from returning if the tank will not be in immediate use.
If the fuel tank is made of steel, it is important to keep it away from water, as water can cause rust to form more quickly on steel surfaces. Keeping the tank clean and dry will also help to prevent rust from returning.
Finally, for those who live in humid climates, consider using a desiccant or dehumidifier to help absorb excess moisture in the air, which can contribute to rust formation. Regularly inspecting the fuel tank for signs of rust and addressing any issues promptly will also help to prevent rust from returning.
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What to do if the tank has holes
If your fuel tank has holes due to rust, there are several methods you can use to repair it. The first step is to drain the tank of any fuel and rinse it with water to remove remnant gas and particles. You can use a water hose for this step and capture the runoff in a trash can filter. You can also use a small electric pump to blow out any remaining liquid. Once the tank is empty, you can begin repairing the holes.
One method is to cut out the damaged sections and weld new metal patches in their place. This process will require repainting the tank. If you don't have welding equipment or the skills to do this, you can use a product like JB Weld Tank Repair, an epoxy resin, to fill the holes. However, this method may only be a temporary fix, and you will need to prepare the surface correctly for the epoxy to stick. You can also use a fuel tank liner to seal pinholes and prevent further rust.
Another method is to use electrolysis to remove the rust from the inside of the tank. This process requires a bike or car battery, clamps, a piece of steel round bar as a sacrificial anode, a plastic spray paint can lid to keep the anode in position, hot water, and sodium carbonate. You can follow BJ's recipe from the Brick House Builds YouTube channel for specific instructions.
Once you have repaired the holes, you will need to coat the inside of the tank to prevent future rust. A product like Red-Kote can be used for this purpose. Plug any holes with rubber plugs, corks, or masking tape, then pour in enough Red-Kote to coat the entire tank. Reinstall the gas cap and rotate the tank to ensure even coverage. Finally, drain any excess product and reinstall the tank.
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Frequently asked questions
There are several ways to treat a rusty fuel tank. One way is to use electrolysis or electrolytic cleaning, which involves using an electric current in an electrolytic bath to get rid of rust. Another way is to use a chemical treatment such as CLR (Calcium, Lime & Rust Remover) or Evaporust. Abrasive materials, which use small mineral particles to scour off rust, can also be used.
Some products that can be used to coat the inside of a rusty fuel tank include Red-Kote and Kreem Coat. It is important to ensure that the surface is rust-free and dry before applying the coating.
If the fuel tank has holes or damage from the rust, it is better to replace it instead of treating the rust. Driving with a damaged fuel tank can be hazardous as it may cause fuel leaks and affect fuel gauge readings. Replacement fuel tanks are not very costly for most vehicles, so it is recommended to replace the tank if it is heavily rusted.
