Do It Yourself Automotive Repair

How to Repair a Gas Tank With a Hole In It


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You should arrange to repair a gas tank as soon as you notice a hole in it. It's easy to detect because you can smell the fumes leaking out of it. A gas tank which has leaks is not only dangerous in that it can lead to a fire, but also wastes a lot of fuel. You could replace the gas tank entirely, but you also have the option of repairing it. There are repair kits available that can be used to do an easy fix.

Car Gas Tank Repair

One of the ways to do this is to use gas tank repair epoxy. This is a gas tank sealant that is readily available in hardware stores. Phenol Novolac Epoxy hangs on to the tank walls during the repair because of its thixotropic features. It is essential to drain any remaining gasoline from the gas tank before repair. Use drywall screws to remove rust. You can shake the tank after adding a small portion of acetone or liquid thinner. Adding one part lacquer thinner or acetone to the gas tank helps remove any residual gas. After you wash the tank, give it time to dry. When the tank is dry, apply duct tape to the holes and other leaking areas to prevent the sealant from pouring out. Mix the two portions of the epoxy sealer and pour it into the tank. Seal the filler hole using a rubber band or a plastic wrap. Shake the tank for some time, which allows the sealant inside to coat properly. Remove the plastic wrap and the remaining sealant and let the tank drain. Scrape out the excess sealant using a knife and leave the tank overnight to cure.

Motorcycle Gas Tank Repair

The procedure here is similar to that of a car gas tank repair. Remove the tank from the bike and pour out any of the remaining fuel. Rinse out the tank and let it dry completely. Cover the holes from outside using duct tape and putty. Pour in the two parts of epoxy gas sealant mixed together. Seal the filler holes and rotate the tank. Make sure that the sealant covers the inside completely before you pour out the remaining sealant.

Other Uses

A gas tank sealant has other functions besides sealing holes in the car or a motorcycle gas tank. It can be used:

  • To reline old potato peeler machines using a coat liner embedded in aluminum oxide
  • For thin cross-section repair of sheared parts, like broken cups or a split leg on a chair
  • As a high strength adhesive
  • As a corrosion and chemical resistant coating in battery compartments
  • To make high quality molds with no shrinkage on curing
  • As a potting compound to sum up electronics
  • To create a non-skid surface by embedding in aluminum oxide
  • To repair leaks in concrete vessels by adding fine sand to make a mortar

The key thing to remember when using the epoxy gas tank sealant is to mix the two parts of the chemicals well enough. This is the only way to ensure you get a strong bond that will completely stop the leak. Read the instructions properly depending on the kind you have purchased.

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