Do It Yourself Gas Tank Repair: 6 Important Safety Precautions

Lead Image
  • 2-4 hours
  • Intermediate
  • 25-50
What You'll Need
Plastic wrapping
Rubber bands
Masking material or duct tape
Acetone or lacquer thinner
Plastic container
Epoxy sealer

If a hole develops in your motorcycle or car gas tank, an immediate gas tank repair job is in order. There is no need to replace the whole gas tank if there is only but a little damage. Repair kits are available that deals easily with a gas tank leak.

Step 1: Remove Gas Tank from Car

When repairing the gas tank, the first step is to remove the gas tank and drain out the remaining fuel.

Step 2: Clean the Gas Tank

Lacquer thinner or acetone can be used to thoroughly clean the gas tank. After that, let the tank sit long enough for the fluid inside to completely dry.

Step 3: Locate the Leak

Now, you should find out the holes in the tank and mark them properly. Make sure that you apply masking tape before using the epoxy sealers. This will ensure that there is no leakage of the sealer which is poured inside. Putty should be used to seal the tank outlets.

Step 4: Pour Sealer into Gas Tank

Use the plastic container to mix the two parts of epoxy sealer. Leave the solution for some minutes and then pour it inside the gas tank. After pouring the sealer, a plastic wrap or a rubber band should be used to seal the tank’s filler hole.

Step 5: Drain Remaining Sealer

The tank should be rotated to ensure that there is even distribution of epoxy sealer across different parts of the tank. After rotation, the filler outlet plug should be removed so that remaining epoxy sealer drains out.

Step 6: Re-install Gas Tank

The last step is to let the gas tank sit long enough to dry out and for the sealer to harden. Finally, the gas tank should be installed again.

Important Safety Precautions While Repairing a Gas Tank

Gasoline should not be used in any case while cleaning the gas tank.

Do not hammer, solder, weld, file, or grind when repairing. A small spark from these instruments can cause an uncontrollable fire in your vehicle or gas tank.

You should wear fuel proof gloves because a small amount of fuel may release when you disconnect the fuel lines.

Fluorescent bulbs should be used instead of incandescent lights because the gasoline vapors may ignite if an incandescent bulb is broken.