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Old 01-31-2011, 07:50 AM   #1
JNRobert OP
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Hole in the Fuel Tank - how to repair?

What's the best way to patch a small hole (it's about the size of a number 6 nail) in a gas tank? It's in an area that doesn't need to be painted as it's covered by plastic fairing parts.

Epoxy? Weld? some special concoction? (I'm hoping epoxy is the answer)

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Old 01-31-2011, 08:59 AM   #2
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How did the hole get there? The reason I ask, i have found that if it's rust, then the metal around the hole isn't very strong and needs to be looked at as well. As to the repair, I prefer to braze it, but I hope others will say good things about epoxy also!
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Old 01-31-2011, 09:33 AM   #3
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How did the hole get there? The reason I ask, i have found that if it's rust, then the metal around the hole isn't very strong and needs to be looked at as well. As to the repair, I prefer to braze it, but I hope others will say good things about epoxy also!
No rust. Accidentally punched a hole with a sharp object. It's small and no other damage and its a new tank.
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Old 01-31-2011, 10:14 AM   #4
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I repaired a large hole in a car gas tank (lowered BMW, high manhole) with a product called Marine-Tex (the gray version for metals). You can find it in most marine product (boat) stores. http://www.jamestowndistributors.com...rine-Tex+Epoxy

It was still holding years later when I sold the car.

JB Weld and dedicated 2 part epoxy gas tank repair products were tried first, they all leaked.
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Old 01-31-2011, 10:17 AM   #5
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tank is steel, alum or plastic?
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Old 01-31-2011, 10:47 AM   #6
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tank is steel, alum or plastic?
Steel
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Old 01-31-2011, 10:47 AM   #7
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Originally Posted by Speedo66 View Post
I repaired a large hole in a car gas tank (lowered BMW, high manhole) with a product called Marine-Tex (the gray version for metals). You can find it in most marine product (boat) stores. http://www.jamestowndistributors.com...rine-Tex+Epoxy

It was still holding years later when I sold the car.

JB Weld and dedicated 2 part epoxy gas tank repair products were tried first, they all leaked.
I'll check it out.
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Old 01-31-2011, 10:53 AM   #8
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Old 01-31-2011, 02:01 PM   #9
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RVDan, does Seal All work - have you used it?
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Old 01-31-2011, 02:09 PM   #10
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I would solder it with an iron & regular (lead/tin) plumbing solder. I have done this a bunch & it works good. Marine Tex is OK, Proseal is what we use to seal aircraft fuel tanks. My experience with Sealall is .....ahhh, mixed results.
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Old 01-31-2011, 04:20 PM   #11
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I would solder it with an iron & regular (lead/tin) plumbing solder. .

For a small hole this is your absolute best bet. If you clean it and flux it correctly you'll never any problems with it.
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Old 01-31-2011, 04:42 PM   #12
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I have patched such holes with sheet metal screws and rubber washers and never had a leak. Way less hassle than any other method.
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Old 02-01-2011, 06:04 AM   #13
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I have patched such holes with sheet metal screws and rubber washers and never had a leak. Way less hassle than any other method.
The little CM200 I picked up last summer had a couple of holes filled with sheet metal screws and rubber washers and they leaked like crazy.

I replaced them with pop rivets (to fill the bulk of the hole) with a little drizzle of that SealAll over them to, well, seal everything up. Worked like a charm, absolutely no leaks.

The SealAll has a thinner consistency than I expected. It's like warm honey. I'm not sure how it would work to patch a hole like that without something (like a rivet) in the hole first.
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Old 02-01-2011, 06:18 AM   #14
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RVDan, does Seal All work - have you used it?
i have used seal all - it does work. it's the cheapest easiest fix - it's not permanent, but i've had it work for a few years at a time.

if the tank shows other signs of deterioration just seal the whole thing with caswell - put some duct tape over the holes so the sealer seals the holes. let it dry for a few days, remove duct tape and your tank is good as new.
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Old 02-01-2011, 06:50 AM   #15
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Solder or braze, it's the best way and you will never have to wonder when the fuel formulation changes whether it's going to eat away the epoxy or rubber.
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