Gas Tank Repair: How to Repair a Hole in the Gas Tank

Lead Image
  • 4-6 hours
  • Beginner
  • 35-60
What You'll Need
Lacquer thinner or acetone
Container for the gas and residue
Drywall screws
Duct tape or masking tape
Plastic container (for mixing the sealer)
Plastic wrap
Epoxy sealer
Rubber band

A gas tank repair is a project you can do at home. Minor leaks on your car’s gas tank can be solved immediately. If you suspect that your car’s gas tank is leaking, you might want to perform necessary check-ups to trace the main culprit and have the problem fixed.

The epoxy repair method is easy to follow and works very well in fixing tiny, unnoticeable holes in your gas tank. It can save you lots of time and money and prevent unwanted consequences. You can resolve minor gas tank problems and leaks by following these steps.

Step 1 - Do an Initial Inspection

First, do a thorough inspection on your gas tank. Feel it with your hands and visually inspect it for tiny holes and minor leakage.

Step 2 - Remove your Gas Tank

Once you have confirmed your suspicions, carefully unfasten the tank and remove it from your vehicle. Completely remove its contents into another container.

Step 3 - Drain any Residue

Add 1 pint of acetone or lacquer thinner into your car’s gas tank. Rotate the tank thoroughly by hand for several minutes and drain the remaining gas and residue. Dispose of the tank scum according to environmental guidelines.

Step 4 - Remove Rust

Clean the interior of the tank by putting several pieces of drywall screws inside the tank. Shake the tank thoroughly for several minutes, then add another pint of acetone or liquid thinner and shake the tank once more.

Step 5 - Sand Your Gas tank

Sand the exterior of your tank to remove unwanted build-up and smooth out the surface to prepare it for the sealing process. Once your tank is completely clean from inside out, rinse it well and let it dry entirely.

Step 6 - Tape up

Place some duct tape or masking tape over the holes, joints, or leaky areas to prevent the sealer from oozing out of the tank. Apply putty to close up the outlet ports.

Step 7 - Seal the Filler Holes

Use rubber bands and plastic wrap to shut the filler holes and avoid unwanted sealer and putty from dripping out.

Step 8 - Seal the Tank

Mix two parts of the Epoxy Sealer together for several minutes then pour the mixture into the tank. Make sure the sealer coats the interior of the tank completely by rotating the tank several times. Take away the plastic wrap, dispense excess sealer and let the tank drain.

Step 9 - Final Clean up

Use a dull knife to remove excess sealer and putty then let the gas tank cure overnight.

Step 10 - Check the Tank

After the gas tank has cured overnight, visually check it for any possible unsealed holes. Double check it by simply applying low pressure air to detect leaks.

Step 11 - Reinstall

Finally, reinstall the tank to your car or vehicle. Make sure every screw is properly tightened and secured. Fill the tank with gas and you are ready to go.