Katerina Swanson
Diesel fuel can cause additional wear on tanks, and it is known to attract water and cause corrosion in steel tanks. A coated fuel tank helps maintain the purity of your fuel, ensuring your engines run smoothly and efficiently. While wire coated with PTFE is a safe bet for fuel tanks, it is unclear whether diesel fuel will strip wire coatings.
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What You'll Learn
PTFE-coated wire is safe for diesel fuel tanks
Diesel fuel can cause corrosion in steel tanks, especially in the presence of ethanol or methanol. While there are industrial coatings that can protect the insides of diesel tanks, these coatings can break down over time, leading to loose particles that clog fuel lines and filters.
PTFE-coated wire is a safe option for diesel fuel tanks. PTFE is used for the white plastic convoluted hoses in many modern fuel tanks. It is also used in mil-spec wire, which is gas-resistant and safe to use in diesel fuel tanks.
Some other options for protective coatings in steel diesel fuel tanks include:
- Sherwin Williams marine tank coatings 4000 series epoxy's
- Damon Industries Red-Kote Gas Tank Liner
- POR-15 Fuel Tank Sealer
It is important to note that not all coatings are suitable for used tanks, and some manufacturers state that their products should only be used on new tanks. Additionally, diesel will dissolve zinc, so a modern polypropylene replacement tank may be a better option.
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Tefzel wire is also a good option
Tefzel wire is typically stranded tin-coated wire with either Crosslinked (M22759/32) or non-Crosslinked (M22759/16) insulation. M22759/16 is a standard wall non-crosslinked (ETFE) Tefzel wire used in many different military, aerospace, and motorsport applications. It can withstand temperatures up to 150º C and voltages up to 600V.
M22759/32 has all the same great attributes as the M22759/16 wire, except for its insulation, which is (XLETFE) crosslinked Tefzel. This allows for less insulation, resulting in a smaller O.D. and lighter weight. In addition, since this wire is crosslinked, the colour profiles can be more pastel.
Tefzel wire is widely used in many industries and applications due to its excellent electrical properties and good resistance to both heat and chemicals. It is commonly found in aerospace, aviation, and motorsport applications. Its high-temperature rating makes it especially suitable for motorsport applications, where high heat is often unavoidable.
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Heatshrink wire is another alternative
While diesel fuel can strip wire coatings, there are a few options for safeguarding wires in such environments. One option is to use wire coated with PTFE, which is used in the white plastic convoluted hoses found in many modern fuel tanks. Another option is to use heatshrink wire, which can provide a layer of protection for wires in fuel tanks.
Heatshrink wire is a versatile option for wire protection, offering both physical and electrical insulation. It is commonly used for wire insulation, wire identification, wire bundling, mechanical protection, colour coding, and more. Heatshrink tubing typically comes in various sizes and configurations, making it adaptable to different applications.
Adhesive-lined heatshrink tubing is a notable variety that provides the highest degree of insulation. This type of heatshrink forms an adhesion layer between the tubing and the wire, creating a water-tight seal. The dual-wall construction consists of an outer layer of polyolefin heat shrink and an inner layer of hot melt adhesive. When exposed to heat, the inner layer melts and flows, and upon cooling, it solidifies to form a secure bond.
When choosing heatshrink wire, it's important to consider the specific requirements of your application. Heatshrink tubing is available in different materials, such as polyolefin, PVC, rubber, PTFE, silicone, and more. Each material has unique properties and is suited for specific temperature ranges and environments. Additionally, heatshrink wire can be used in conjunction with other protective measures, such as sealing the fuel tank or using appropriate wire coatings, to further enhance the protection of the wires.
In conclusion, heatshrink wire is a reliable alternative for safeguarding wires in diesel fuel environments. It offers versatility, strong insulation, and mechanical protection. By selecting the appropriate materials and sizes, heatshrink wire can be tailored to meet the specific demands of your application. Combining heatshrink wire with complementary protection methods can further bolster the defence against diesel fuel stripping wire coatings.
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Seal the wire to prevent wicking
To prevent wicking, it is important to seal the wire. Wicking occurs when the wire carries heat, allowing solder to experience capillary forces. This can be prevented by pinching the wire with a heatsink clamp as solder cannot wick if the copper is too cold.
There are various ways to seal wires. Firstly, you can use a heat-shrinkable jacket over a group of wires to create an environmental barrier. However, to prevent wicking, it is important to seal the ends of the wires where the jacket stops. This can be done using a hot melt adhesive under the heat-shrink tubing material at each end.
Another option is to use an adhesive-lined heat shrink tubing. However, these tubings have been found to have insufficient adhesive to seal cables made from multiple wire strands. Therefore, it is recommended to use Z-Block Tape, which is a hot melt tape, in conjunction with wrap-around PRT material. The Z-Block Tape is cut to provide a water-blocked area at least 1-inch long at the end of the finished cable. The PRT tubing is then installed around the wires, ensuring that the adhesive faces away from the wiring. The non-adhesive edge of the tubing should be positioned parallel to the exposed adhesive. Once the adhesive is covered, begin bonding the tubing overlap to the adhesive, avoiding contact with your fingers.
Additionally, you can use PTFE-coated wire, which is a safe option for fuel tanks. DR25 heatshrink also holds up well in fuel, and SCL can be used for any connection points.
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Coatings prevent rust and corrosion
Coatings are essential to prevent rust and corrosion, especially in harsh environments. From industrial equipment to everyday tools, these coatings protect metals and extend their lifespan.
There are various coatings available that can prevent rust and corrosion. For instance, galvanizing compounds, such as ZRC, are popular for their anti-corrosive properties. Sacrificial zinc-rich coatings, such as ZRC, protect steel by galvanic action. When zinc is in contact with steel in a moist environment, zinc ions are released, creating a current that prevents steel ions from corroding. Zinc-rich primers are often used as a base layer under paint, providing an additional layer of defence. Polyurethane coatings are also known for their flexibility and UV resistance, making them ideal for outdoor metal surfaces. They create a strong barrier against environmental elements, reducing the risk of rust.
Epoxy coatings are another popular option for rust prevention due to their excellent adhesion and moisture resistance. They form a seamless protective layer, tightly bonded to the metal surface, that prevents water and oxygen from reaching the substrate. Powder coatings are another environmentally friendly and effective solution for preventing rust on metal surfaces. They are applied using an electrostatic process, forming a thick, durable layer that protects against moisture and corrosion.
For those seeking a DIY solution, a combination of linseed oil and paint can be effective. By boiling linseed oil and applying it to clean, dry metal, a flexible bond coat is created that acts as a moisture barrier. Following this, a coat of paint, such as Rustoleum gloss, can be applied for added protection.
In terms of wire coatings, wires coated with PTFE are a safe option for use in fuel tanks. PTFE is commonly used in the white plastic convoluted hoses found in modern fuel tanks. Additionally, coatings like POR-15 Fuel Tank Sealer are formulated for metal and act as a liner to stop rust, corrosion, and small fuel leaks. While coatings can be effective in preventing rust and corrosion, it is important to note that some coatings may not be compatible with certain fuels or materials. For example, diesel fuel contains ethanol, which can attract water and cause corrosion in steel tanks. Therefore, it is crucial to select the appropriate coating for the specific application.
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