Rajan Wilcox
Whether or not your motorcycle fuel tank is salvageable depends on a number of factors, including the extent of the damage, the cost of repair, and your mechanical abilities. While some suggest that it is more cost-effective to simply replace the tank, others advocate for the use of DIY methods such as gravel, white vinegar, and oil to clean and remove rust. Others still recommend more intensive methods such as cleaning, sandblasting, and sealing the tank, or using plastic treatments and electrolysis to restore it. Ultimately, the decision to salvage or replace a motorcycle fuel tank depends on individual preferences, skills, and resources.
Is my fuel tank salvageable?
| Characteristics | Values |
|---|---|
| Cost of a new tank | $100-$150 |
| Cost of cleaning and lining | More than $100 |
| Time taken to clean a tank | 3 weeks |
| Time taken to clean a tank with the proper technique | 1.5 weeks |
| Methods to check if the tank is salvageable | Throwing gravel in the tank and shaking it, checking for leaks |
| Methods to clean the tank | White vinegar, compressed air, Marvel Mystery oil, sandblasting, plastic treatments, electrolysis, gravel |
| Other methods | Soldering pin holes, using a blowtorch |
| Other suggestions | Buying a new tank, selling the motorcycle for parts |
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What You'll Learn
Cleaning methods: gravel, white vinegar, or sandblasting
Cleaning methods for a motorcycle fuel tank depend on the severity of the damage and the equipment available. Here are three methods that can be used to clean and salvage a rusty motorcycle fuel tank: gravel, white vinegar, and sandblasting (or media blasting).
Gravel
This method is recommended as a first step to assess the severity of the rust and to remove loose debris. It is also the cheapest method, as it only requires a couple of handfuls of gravel and a strong arm. Pour the gravel into the tank and shake vigorously for around 15 minutes. Then, dump out the gravel and debris and inspect the inside of the tank. This process will give a better idea of whether the tank can be salvaged and what further steps may be needed.
White Vinegar
White vinegar is an effective, inexpensive, and safe solution for removing rust from a motorcycle fuel tank. The acetic acid in vinegar dissolves the rust, and the process is relatively simple. Pour around three gallons of white vinegar into the tank and let it sit for five to six days. Occasionally stir the vinegar during this period. After the vinegar has done its job, empty the tank and blow compressed air to dry it out. Finally, add a couple of quarts of oil, slosh it around, and then drain.
Sandblasting (or Media Blasting)
Sandblasting is a more heavy-duty method for removing rust and requires specialized equipment. It involves propelling abrasive materials, such as sand or other media, at high speeds to strip away rust and old paint. This process can be very effective, but it may not be suitable for all tanks, especially if they are made of thin metal. Sandblasting can be done professionally or as a DIY project, but it is important to take the necessary safety precautions, such as wearing protective gear and ensuring proper ventilation.
Other methods for cleaning and de-rusting a motorcycle fuel tank include using commercial rust removers, electrolysis, and chemical solutions like muriatic acid. Each method varies in complexity, cost, and effectiveness, so it is important to assess the condition of the tank and choose the most suitable approach.
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Plastic treatments and sealers
There are several products available for sealing plastic fuel tanks, including the Caswell Epoxy liner, Flowliner Armour coat tank sealer, and POR-15. These products can be applied to the inside of the tank to protect the plastic from ethanol attack and prevent leaks. It is important to note that the tank should be cleaned, stripped of paint, and allowed to breathe in a warm environment before applying any sealants to ensure the solvents have migrated out of the plastic.
Some people have also had success with "plastic welding" their fuel tanks, which can be done cheaply and quickly at a motorhome repair shop. Others have suggested using gravel or marbles inside the tank and shaking vigorously to remove rust and get a better idea of whether the tank can be saved.
Before applying any treatments or sealers, it is important to consider the cost and effort involved in salvaging the tank versus simply replacing it with a new one. Fuel tanks can often be purchased for relatively low prices, and the time and effort spent on repairs may not be justified. However, for some, the tinkering and learning experience of fixing up an old tank can be rewarding.
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Electrolysis
Firstly, you should clean out the tank of any fuel, disposing of the waste fuel safely. You can then place loose nuts and bolts inside the tank and shake them around to loosen some of the rust. After dumping these out, you will need to set up a sacrificial steel anode so that it extends into the tank without touching the sides. The anode must be clamped to the charger and kept in place with wood, an old tennis ball, tape, or something similar.
In a large bucket, mix water and washing soda (or soda crystals) to fill your tank. Use about a tablespoon of washing soda per gallon of water. Pour this mixture into your tank and grab your battery charger. Turn on the power and wait. The solution will start fizzing and bubbling, and will eventually turn gunky as the rust is lifted from the metal. You can leave the solution for anywhere from 24 hours to a week, depending on how bad the rust is.
After removing the electrode and rinsing and drying the tank, you can apply a sealer to the tank. Some sources suggest using Red-Kote Fuel Tank Sealer and Liner, while others recommend half a litre of 2-stroke oil or simply filling the tank with gasoline.
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Soldering pinhole leaks
A fuel tank with pinhole leaks can be salvaged by soldering, but it is not recommended as the area surrounding the pinhole is usually weak metal that will eventually give way. Before soldering, the tank must be cleaned, and all rust must be removed. This can be done by using a couple of handfuls of gravel and shaking the tank for 15 minutes, or by using three gallons of white vinegar, letting it sit for 5-6 days, and then blowing compressed air to dry it out.
After cleaning, the tank should be checked for leaks. If there are small pinhole leaks, they can be soldered, but it is important to ensure that the tank is completely dry, including any vapors, before beginning the soldering process. Silver soldering kits are available at local hardware stores for around $15.
As an alternative to soldering, some products can be used to patch fuel tank leaks, such as Seal-All, which is available at most hardware and automotive parts stores for around $1.50. KREEM Tank Liner is another option that can fill in small holes and prevent leakage from hairline cracks and seam pinholes. If the tank is rusty, it is recommended to coat the inside with KREEM or a similar tank coating product.
For a more permanent solution, welding the leaks is an option, but it may be challenging to weld small pinholes. Additionally, electrolysis can be used to clean out the tank, and then a coating can be applied to the inside of the tank to prevent leaks.
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Cost-benefit analysis of salvaging vs. replacement
The cost-benefit analysis of salvaging versus replacing a motorcycle fuel tank depends on several factors, including the severity of the damage, the availability of replacement parts, and cost implications.
Salvaging the Fuel Tank
Salvaging the fuel tank can be a more cost-effective option if the damage is minimal and can be addressed through cleaning and minor repairs. Some common methods for salvaging a fuel tank include:
- Using gravel or large nuts and bolts inside the tank, shaking vigorously, and then washing out the rust with gas.
- Soaking the tank with a liquid solution like white vinegar or commercial rust removers, followed by compressed air drying and the application of oil to remove residual rust.
- Employing plastic treatments that can be poured directly into the tank and sloshed around, though this may damage the original paint and require repainting.
- Applying electrolysis to clean the tank, followed by checking for leaks and using inner coatings to address them.
The advantages of salvaging include the potential for lower costs if the damage is minor and can be effectively addressed through DIY methods. It also allows for the preservation of the original fuel tank, which may be desirable for motorcycle enthusiasts or for rare tank models.
However, salvaging may not always be feasible, especially if the fuel tank has extensive rust or damage. The process can be time-consuming and labour-intensive, requiring multiple treatments and coatings. There is also a risk of new leaks appearing during the derusting process, which can be challenging to address without professional welding or soldering.
Replacing the Fuel Tank
Replacing the fuel tank involves purchasing a new or used fuel tank that is compatible with the motorcycle's make and model. Replacement tanks can often be found at motorcycle salvage yards or online marketplaces.
The benefits of replacement include the assurance of a functional and reliable fuel tank, especially if the original tank is severely damaged or corroded. Replacement tanks may also be more readily available and require less time and effort than salvaging, allowing for a quicker resolution to the issue.
However, the cost of replacement parts can vary, and certain fuel tanks, especially rare or unique models, may be more expensive. Additionally, the process of replacing the fuel tank may require additional labour costs if professional installation is needed.
The decision between salvaging and replacing a motorcycle fuel tank ultimately depends on the specific circumstances. For minor issues and those with mechanical skills, salvaging can be a cost-effective and rewarding option. On the other hand, replacement may be more suitable for severe damage, availability of replacement parts, and when time and convenience are prioritised over cost. It is essential to weigh the financial and practical considerations before making an informed decision.
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Frequently asked questions
First, you need to inspect the tank for leaks. If there are no leaks, you can then try to clean the tank.
There are several methods for cleaning a rusty motorcycle fuel tank. One method is to use a couple of handfuls of gravel, shake the tank for 15 minutes, then dump out the contents and inspect the inside of the tank. Another method is to use white vinegar, leaving it in the tank for 5-6 days, then emptying the vinegar and drying the tank with compressed air before adding a couple of quarts of oil.
There are plastic treatments that can be poured into the tank and sloshed around. You can also use electrolysis to clean the tank, then use an inner coating like POR 15.
This depends on the cost of repairing the tank versus the cost of buying a new tank. If the repair cost exceeds the replacement cost, it may be more economical to simply replace the tank. Additionally, consider your mechanical abilities and the amount of time you are willing to spend on the repair.
