Katerina Swanson
If you're looking to get your fuel tank sealed, there are a few options available to you. Firstly, it's important to note that fuel tank sealing products are designed to fix issues with rust, corrosion, and small fuel leaks. These products are available from brands such as POR-15, KBS Coatings, and Eastwood, and can be purchased online from sites like Amazon and BobIsTheOilGuy. Before applying a fuel tank sealer, it's essential to clean the tank and remove any existing rust, varnish, or contaminants. The tank should then be dried and prepared with an acid treatment or a metal etching product to ensure the sealer adheres properly. Finally, the sealer can be poured into the tank and the tank rotated to ensure all surfaces are coated.
| Characteristics | Values |
|---|---|
| Fuel tank sealing products | POR-15 Fuel Tank Sealer, Gold Standard Tank Sealer, Red Kote Tank Sealer, Eastwood Gas Tank Sealer |
| Where to buy | Amazon, KBS Coatings, POR-15, Eastwood |
| Preparation | Degrease, remove built-up gum or varnish, clean with acid or phosphoric acid tank cleaner, treat with Ospho, coat with zinc phosphate, etch with POR-15 Metal Prep or RustBlast |
| Application | Pour entire can of sealer into the tank, rotate tank to ensure even coverage, drain excess sealer, allow to air dry for 96 hours |
| Tips | Ensure tank is free of plastic parts, do not reuse sealer, do not let sealer form puddles, use in a well-ventilated area |
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$44.99 $49.95
What You'll Learn
Using a fuel tank repair kit
Fuel tank repair kits are available from several retailers, including Home Depot, Versachem, Permatex, and KBS Coatings. These kits can be used to repair gasoline and diesel fuel tank leaks caused by pinholes, rust-outs, hairline cracks, and holes. The repair process typically involves draining the tank, cleaning and preparing the surface, applying a sealant or epoxy, and allowing the repair to cure. Here is a step-by-step guide on using a fuel tank repair kit:
Step 1: Vent the Tank
Remove the gas cap to allow the tank to ventilate. Ensure that you are working in a well-ventilated area to prevent the buildup of fumes.
Step 2: Drain the Tank
If the leak is large, you may need to drain the tank completely. If the leak is small, you can temporarily stop it by rubbing the enclosed mastic stick or putty over the hole.
Step 3: Prepare the Surface
Clean the area around the leak by removing any oil, grease, tar, dirt, or loose rust. Sand the area to bare metal, creating a smooth surface that extends about 1 inch beyond the damage. Wipe away any dust or debris.
Step 4: Apply the Sealant or Epoxy
If using a sealant, follow the instructions on the kit for mixing and application. Pour the sealant into the tank and slowly rotate the tank to ensure that the sealant coats the inside evenly. Drain any excess sealant and allow the tank to air dry in a well-ventilated area. If using an epoxy, cut a piece of fiberglass cloth to cover the sanded area. Mix the epoxy quickly, as it will start to harden within a few minutes. Firmly apply pressure to the epoxy pouch to burst the seam, and then spread the epoxy onto the damaged area.
Step 5: Cure Time
Allow the repair to cure completely before refilling the tank and using the vehicle. Cure times can vary depending on the product and temperature. Some products may take up to 96 hours for maximum cure. Always refer to the manufacturer's instructions for specific cure times and recommendations.
It is important to note that some fuel tank repair kits are not suitable for use on plastic fuel tanks. Always read and follow the safety precautions and instructions provided with the kit.
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Removing rust
Rust in a fuel tank is caused by water trapped inside, which can occur due to condensation, refuelling in the rain or snow, or water pooling at the bottom of the tank. To remove rust from a fuel tank, you can use a rust remover, such as Evaporust, CLR (Calcium, Lime & Rust Remover), or phosphoric acid tank cleaner. Another option is to use electrolysis, which involves using a sacrificial anode made of steel or iron, a battery charger, and a solution of Arm & Hammer Super Washing Soda. This process can take 8-10 hours and may require multiple sessions.
Step 1: Prepare the Sacrificial Anode
- Create a sacrificial anode by using a steel or iron rod. Avoid using stainless steel as it can produce toxic substances during the process.
- Fashion a collar out of scrap wood to suspend the anode inside the tank without letting it touch the tank's surface.
Step 2: Set Up the Battery Charger
- Attach the negative lead from the battery charger to the fuel tank.
- Attach the positive lead to the sacrificial anode.
- Dial the charger to a suitable setting, such as the 10-amp setting, to avoid overheating.
Step 3: Perform Electrolysis
- Turn on the battery charger and let the setup run for 8-10 hours.
- In between sessions, extract the sacrificial anode, clean it by knocking off accumulated rust, drying it, and sanding it to remove stubborn bits.
- Replace the electrolytic solution each time.
Step 4: Neutralize Rust and Prepare for Sealing
- After removing the rust, neutralize any remaining rust and prepare the metal for sealing.
- Use a product like RustBlast, an acid metal etch that neutralizes rust, etches the metal, and leaves a zinc phosphate coating for better adhesion of the sealer.
- Pour RustBlast into the dry tank and rotate the tank every 5 minutes for at least 30 minutes to ensure even coverage.
- You can also put a length of chain, nuts, and bolts, or BBs inside the tank to agitate and help remove rust.
- Rinse the tank thoroughly with water.
Step 5: Seal the Fuel Tank
- Once the tank is clean and dry, seal it with a suitable fuel tank sealer, such as the KBS Gold Standard Tank Sealer or POR-15.
- Pour the entire can of sealer into the fuel tank and slowly rotate the tank to ensure the inside is thoroughly and evenly coated.
- Drain any remaining sealer from the tank, ensuring it doesn't puddle as this can affect adhesion.
- Allow the tank to air dry in a well-ventilated area for up to 96 hours for maximum cure.
It is important to note that removing rust and sealing a fuel tank can be a complex process, and it is always recommended to consult a professional or seek advice from experienced individuals before attempting any repairs or modifications.
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Sealing with a zinc phosphate coating
Sealing a fuel tank is a common procedure to prevent rust and corrosion. Rust is caused by water trapped inside the fuel tank, which can occur due to condensation, refuelling in the rain or snow, or water pooling at the bottom of the tank.
One method to seal a rusty fuel tank involves using a sealant kit, such as the POR-15 fuel tank sealer kit or KBS Coatings' Auto Fuel Tank Sealer Kit. These kits typically include the necessary materials for cleaning, rust removal, and sealing the tank. The process involves cleaning the tank, removing rust, and coating the inside with a sealant.
Another option for sealing a fuel tank is to use a zinc phosphate coating. This process, offered by companies like Henkel Adhesives, is a trusted pretreatment that prepares metal surfaces for painting or coating. It can be applied to a wide range of metals, including steel, hot-dipped or electrogalvanized steel, zinc-nickel alloys, and aluminium.
The zinc phosphate coating process involves the following steps:
- Cleaning and surface conditioning: The metal surface is cleaned and prepared using a suitable method, such as sponging, spraying, or immersion.
- Conversion coating: Depending on the substrate, a traditional zinc phosphate spray or immersion coating is deposited on the surface. For aluminium, the process is modified to prevent the zinc phosphate coating from depositing directly, and a nanoceramic conversion coating is applied instead.
- Post-treatment (optional): A post-treatment or sealer can be applied to reduce the porosity of the surface, improving its adhesion and corrosion resistance. This step is especially beneficial for long-term performance, particularly in the case of aluminium.
The zinc phosphate coating provides excellent corrosion protection and enhances paint adhesion. It changes the chemical nature of the surface, increasing alkaline resistance and paint durability. This process is commonly used in automotive manufacturing to protect steel surfaces from corrosion and improve their resistance to wear.
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Sealing with epoxy
Sealing a fuel tank with epoxy is a common practice for salvaging old gas tanks. This method can be used to seal holes and cracks in the tank. Firstly, it is important to clean the tank of any oil, gasoline, or grease. This can be done by pouring a solvent such as acetone or lacquer thinner into the tank and rotating it to sluice the sides. The contaminated solution should then be disposed of.
Next, any old coating should be removed using a paint stripper containing methylene chloride. Drywall screws can then be placed in the tank and shaken vigorously to dislodge any loose particles of rust. The tank should then be rinsed with a solvent and dried. Duct tape can be applied to any seams, holes, or porous areas.
The epoxy is then ready to be mixed and applied. The contrasting-coloured materials are mixed together until a uniform colour is achieved. The epoxy should be applied within 30 minutes of mixing, and any excess material should be removed before it hardens. The epoxy will set within an hour but requires 24 hours to fully cure.
Phenolic novolac epoxies are a new breed of chemical-resistant materials that can withstand permanent immersion in harsh solvents, fuels, and oils. This type of epoxy has better bond strength than single-component products, with strengths of up to 3000 PSI. It also has a higher thixotropy, resulting in a thicker overall coating.
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Using a professional service
If you are looking to get your fuel tank sealed, there are several professional services you can turn to. Many companies offer fuel tank sealing kits, which can be used to seal your tank yourself. However, if you prefer to have a professional do the job, there are also auto repair shops and mechanics that offer fuel tank sealing services.
One option for professional fuel tank sealing is to contact a local mechanic or auto repair shop. They will have the experience and expertise to properly seal your fuel tank and ensure that it is done safely and effectively. You can find mechanics and auto repair shops in your area by searching online or asking for recommendations from friends or family.
Another option is to reach out to companies that specialize in fuel tank sealing. These companies often have a range of sealing products and services, and their technicians are highly trained in the process. They can guide you through the entire procedure, from selecting the right sealant to properly preparing and sealing your tank. Some reputable companies offering fuel tank sealing services include KBS Coatings and POR-15.
When choosing a professional service for fuel tank sealing, it is important to consider their experience and reputation. Ensure that they have a track record of successfully sealing fuel tanks similar to yours. Read reviews, ask for references, and inquire about their specific process to gauge their expertise and professionalism.
Additionally, keep in mind that fuel tank sealing can be a complex and time-consuming process. It typically involves multiple steps, including cleaning the tank, removing rust or old sealant, preparing the metal surface, and properly applying the sealant. A professional service will be equipped with the necessary tools, materials, and knowledge to handle each step effectively. They will also be able to advise you on any necessary precautions and provide guidance on maintaining your fuel tank after the sealing process.
By opting for a professional service, you can have peace of mind knowing that your fuel tank sealing is done correctly and safely. They will ensure that the sealant is compatible with your tank's material, address any unique challenges or issues, and provide a durable and long-lasting solution. Remember to follow any post-sealing instructions provided by the professionals to maximize the effectiveness and longevity of the sealed fuel tank.
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Frequently asked questions
You can get a fuel tank sealed at a mechanic's shop or auto body shop. You can also seal it yourself with a fuel tank sealer kit.
A fuel tank sealer kit contains the necessary materials for cleaning, rust removal, and sealing a fuel tank.
There are several fuel tank sealer kits available on the market, including those offered by KBS Coatings, POR-15, and Eastwood. Reviews for these products are generally positive, but some users have reported issues with the sealers coming off in large chunks.
The process of sealing a fuel tank typically involves cleaning the tank, removing existing rust, and coating the inside of the tank with a sealant. Specific instructions may vary depending on the product used.
The cost of getting a fuel tank sealed can vary depending on the service provider and the severity of the issue. Sealing a fuel tank yourself with a kit can be a more cost-effective option, but it may require more time and effort.
