DIY gas tank filler repair

In detail: do-it-yourself repair of a gas tank neck from a real master for the site my.housecope.com.

Fuel tanks for cars can be made of various materials, the main of which are sheet structural steel or conventional plastic, which is rather a composite material.

But no matter what the fuel tank of a car is made of, under certain conditions it can get holes and cracks. Moreover, it may be a microcrack, almost invisible to the eyes, but it is quite enough for gasoline to ooze, filling the car interior with unpleasant vapors.

A crack or a hole in the tank can result from corrosive processes, but this applies exclusively to metal tanks and does not at all apply to composite tanks. However, a crack can also appear on the surface of the composite tanks.

So let's find out how fuel tank repairs are done.

Car fuel tank repair methods

We can conditionally distinguish two types of methods that can be used when repairing fuel tanks. The first technology is hot (welding, brazing). The second technology is cold (the use of adhesives and patches).

Hot methods of repairing a fuel tank are technically difficult and require certain skills and abilities. In addition, welding or soldering equipment is required, as well as an understanding of how thin-walled structures can be welded or soldered.

Cold methods of repairing a fuel tank are somewhat simpler. You only need to adhere to a certain and fairly simple technology. In order to repair fuel tanks, use the so-called "cold welding" or epoxy resin in combination with fiberglass.

Video (click to play).

Repair of the fuel tank using "cold welding"

There is nothing complicated in this method. They buy a special two-component compound, which is sold in almost all hardware stores or car dealerships. Before applying cold welding, the surface in the damaged area is cleaned of dirt, then cleaned with sandpaper and degreased, for example, with a nitro solvent. It is not recommended to degrease with motor gasoline, as a thin layer of oil film may form.

After that, cut off a piece of cold welding with a knife and knead it thoroughly with wet hands. It is better to work with gloves so that you do not wash your hands later. After that, the defect on the fuel tank is carefully covered with cold welding. And it only remains to wait until the composition polymerizes.

Such a repair of fuel tanks is very simple, but it should be noted that the patch obtained in this way begins to crack over time due to vibrations that are inevitable during vehicle operation.

Repairing a fuel tank with epoxy

This method of repairing a fuel tank is more reliable and is suitable for both metal and plastic (composite) tanks. Its essence lies in the fact that a patch of several layers of fiberglass on epoxy resin is applied to the place of the defect.

The surface of the tank in the place of damage must be prepared (cleaned and degreased). Next, the epoxy is diluted in accordance with the instructions. But besides this, aluminum powder is added to the resulting resin in a ratio of 1:10 (one part of aluminum powder to 10 parts of resin). This filler makes the resin less brittle and more durable.

Several patches of fiberglass are cut out (3-4). After that, a layer of resin is applied with a brush and a patch of fiberglass is applied, then the next layers of resin and fiberglass are applied on top.The patch is rolled with something rubber to completely remove the air. Thereafter, it cures for about 24 hours. The last stage: the surface is smoothed with sandpaper.

The advantage of this repair method is that the patch is durable due to fiberglass and is completely not susceptible to cracking. It completely seals the tank and epoxy is completely indifferent to car fuels, be it gasoline or diesel.

Repair of a plastic fuel tank by soldering

It must be said that this method is not very reliable, since it is difficult to ensure a normal seam around the entire perimeter of the plastic patch.

The method is as follows. It is necessary to find a plastic suitable in its composition to the plastic of the tank. After that, a small patch is cut out of this material. First, the patch is tacked in place with super-glue, and then, using a powerful soldering iron, it is soldered around the entire perimeter of the patch.

It will hold on tightly, but it is not always possible to ensure normal tightness. Microcracks may remain somewhere, which, in principle, can be eliminated with the help of a sealant. But it should be said that the sealant can gradually deteriorate under the influence of gasoline. So this method, although simple, is not reliable enough.

Repair of a metal fuel tank by welding and brazing

It should be understood that with such repair methods, there is always a danger that gasoline vapors that are in the fuel tank may flare up. In order to avoid a fire, the tank is thoroughly washed out of fuel, and only then soldering or welding is used.

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Thus, the tank can be welded or soldered only after a certain amount of time required for the fuel vapor to completely disappear.

The safest option is to fill the tank with water or an inert gas to avoid flare-ups. The most popular welding method, which gives the greatest reliability, is argon welding.

The second most reliable method is soldering with a special solder. In this case, the tank is not filled with water. But with both methods, the neck should be kept open so that the air inside, expanding when heated, does not deform the tank.

Fast temporary repair of fuel tanks

The tank can be temporarily repaired by using a common screw and rubber gasket. If a hole appears, albeit a small one, it should be slightly widened to fit the size of the screw. Then a piece of rubber is put over the screw and the screw is screwed into the hole. It is only important to guess the size of the hole so that the screw is screwed in normally.

While trying to refuel “under the neck”, a jet of gasoline and a puddle on the asphalt were found under the car.
A detailed examination revealed the following. The filler pipe (from the filler neck to the gas tank) runs outside the body in the wheel arch and is protected by a plastic cover. The space between the casing and the body was completely clogged with earth, and the pipe under such conditions rotted to the extent of metal stratification, even gasoline began to flow through it. There are also traces of rust on the body itself in this place.

Of the repair options, we see replacing the pipe with a new one (from 5000 on Exist) or from disassembly, or replacing it with a gas-resistant rubber hose with clamps (while this option is more pleasant).

I wrote it just in case, suddenly someone will find it interesting and useful. Just in case, take a look at how you are doing 🙂

The life of a driver is sometimes difficult - the road is fraught with many surprises. However, most of the troubles arise from malfunctions of the "iron horse": an overheated engine, a punctured wheel or a muffler that suddenly fell off - the list of such force majeure can be continued indefinitely. One of these problems is a punctured gas tank on the road, and this article will focus on eliminating this malfunction.

Damage to the gas tank is really unpleasant, and if a fuel leak is detected, it is necessary to urgently take measures that will allow you to get to the service station for a high-quality repair or replacement of the tank... The problem will have to be solved quickly and competently: you cannot wait for help and lose precious fuel, and it may be too far to the nearest settlement.

There are several ways to notice a fuel leak:

a sharp appearance of the smell of gasoline in the car;
a puddle of gas directly under the gas tank;
rapid lowering of the fuel level sensor needle;
excessive increase in fuel consumption.

Fuel loss is a signal to look for and eliminate the breakdown. The situation is simplified by the fact that the gas tank, which has holes in the upper part, will still allow you to get to the workshop, and if there are holes at the bottom of the tank, it will not be difficult to notice them. Usually they occur at the bottom: the cause can be, firstly, various mechanical influences, and secondly, corrosion, corroding the tank on both sides.

The most common way to repair a gas tank with your own hands in the field is cold welding. The same method is used by specialists in auto repair shops to bring the tank into proper condition. The repair process itself will look like this:

first, using sandpaper, it is necessary to clean the damaged area (if this is not done, then the applied patch will soon fall off);
then a mixture of epoxy resin and hardener is prepared (you can use a heated engine to heat the mixture);
after saturating the fabric patch with the mixture, it must be applied and pressed to the tank.

This method of repairing a gas tank has a lot of advantages:

the result is of sufficient quality, and in the future you can do without replacing the tank;
the repair requires a minimum of materials and efforts.

To implement the second method of eliminating a gas tank leak, fiberglass and epoxy resin are used. The repair is very simple, and the work algorithm looks the same as for cold welding:

first of all, the hole in the tank must be cleaned and degreased;
after that, a resin-impregnated fiberglass cloth is applied to the surface (usually two layers of material are applied);
after the patch dries, it is usually treated with an anti-corrosion layer.

This method is quite reliable and simple, and if you protect the patch from corrosion, then such a tank will be able to

work for quite a long time. True, on the road, the necessary materials are not always at hand, and in this case they can be replaced with ordinary superglue and rags. A patch made of several layers of fabric impregnated with glue will allow you to safely get to the workshop and carry out a quality repair.

Another interesting method of repairing a gas tank with your own hands is the installation of a rubber gasket. Usually, a serious leak is eliminated in this way, provided that the tank cannot be repaired in other ways. To work, you need a screwdriver, a rubber gasket and a bolt with a nut. The repair will look like this:

the breakdown of the tank expands so that a bolt can be inserted into it;
a bolt with a washer installed on it is pushed through the neck of the tank directly into the hole that must be removed;
a gasket is installed on the outside and secured with a nut.

From the point of view of reliability and efficiency, such a patch is the best option for repairing a tank. The result is so good that sometimes, after such a repair, the driver manages to drive on the repaired tank for more than one year. However, it is not worth delaying with a high-quality repair of the gas tank - as a rule, the appearance of holes in the tank indicates its deterioration (unless the hole appeared as a result of a strong impact on the relief).

"Folk ways" of repairing a gas tank on the road

To carry out field repairs of the tank, you must carry with you materials that allow you to implement at least one of the above methods: they will not take up much space, and the benefits can be significant. But there are times when the necessary materials are simply not available, or the damage to the tank looks very insignificant. In such a situation, you can solve the problem in one of the popular ways:

Find out in our material how to repair a muffler with your own hands.
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Sometimes the hole in the gas tank is almost imperceptible, and fuel does not flow through it, but drips slowly. If the cause of this leakage is a small crack, then rub it well with soap. Of course, such an action cannot be called an effective repair, but it will be quite enough to get to the nearest service station.
Having found a small hole in the tank, you can act differently: take a small self-tapping screw and screw it into the hole. If you pre-lubricate the self-tapping screw with soap and use a gasket, then urgent repairs can be postponed until you arrive in the village.
There is another old method that allows you to get to the auto repair shop even with critical damage to the tank. Every experienced driver knows about this method of solving the problem: a plastic bottle or canister is taken, fuel is poured into it, and then a fuel hose is supplied and fixed to it. Of course, this is far from the most elegant solution to the problem, but you can get to the service station this way.

Having corrected the problem in the most suitable way, you can end the trip, and after that, examine the tank in detail for the presence of other leaks and malfunctions. It would be best to entrust the dismantled gas tank to specialists who can determine exactly how suitable it is for driving.

In conclusion, it should be said that the most correct way to eliminate the leakage of the gas tank is to replace it (especially if the old tank has served long enough). Of course, changing an almost new tank after every scratch is not worth it - for this there is welding and soldering, which are carried out without problems at any service station - but it is extremely undesirable to wait for the complete wear of the gas tank.

There are several ways to repair a gas tank on the road, and all of them are quite simple, but it would be much better to carry out preventive work in a timely manner - and then there will be no need to urgently fix the problem. However, even if the car is maintained in good condition, an extra tube of glue or a couple of bolts in the trunk will never hurt - a variety of problems can manifest themselves on the road.

Many modern vehicles are equipped with plastic elements in their construction. There have been attempts to produce entirely plastic-based bodies, but due to globalization, automakers continue to stubbornly use metal as the basis for their production. But some automotive plastic parts are gradually replacing conventional metal products.

How to repair a plastic gas tank

One of these elements is a plastic gas tank, which has undeniable advantages over its metal counterpart:

The photo shows a plastic gas tank. Let's talk about its cons

Despite the relevance of modernizing the gas tank, the transition from iron to plastic was slowed down for a number of reasons. At the beginning of 2000, new environmental standards were issued, into which plastic fuel tanks did not fit, due to the fact that, despite all the tightness of the structure, the leakage of fuel into the environment was more than 20 milligrams per day. The bulk of the losses occurred on the outside fuel intake lines. At present, the problem has been overcome by shifting the elements of the fuel delivery system to the tank, and by using a multilayer structure.This modernization has reduced the likelihood of fuel leakage to zero, as long as your hands do not shake when refueling the car.

Today, about 70% of new cars are equipped with plastic gas tanks, but problems that cause inconvenience to owners remain unresolved:

The noise from the fuel tank disturbs the sound atmosphere in the vehicle interior. Of course, if a person drives cars of the VAZ family, such as VAZ 2107 or VAZ 2110, then this nuance will be unimportant to him. At the same time, this discomfort is very annoying to the owners of Hyundai Sonata and Kia Sid;
Internal pressure regulation. Due to the fact that plastic lends itself well to deformation, each change in pressure leads to contraction and expansion of the container. These actions lead to fractures of the joints on the neck under the lock of the hatch cover or in other similar mates.

Despite the potential for trouble, most drivers install plastic gas tanks on their cars. The advantages of these products outweigh the disadvantages. For owners of Mitsubishi Pajero, the anti-corrosion resistance of plastic is relevant. The owners of the VAZ 2114 are interested in the economic component, because the maintenance and repair of a plastic gas tank is cheaper than a metal one.

If you find a fuel leak in the area of the gas tank, you should stop using the vehicle for the sake of your safety and those around you. Repairs should be carried out on a removed and thoroughly rinsed container. Thus, it is possible to conduct a complete revision of the product that has broken through and pinpoint the location of the problem area. Most often, these are longitudinal cracks or destruction of the welded seam connecting the elements of the fuel system, which is a consequence of mechanical impact from the outside.

How to repair a plastic gas tank with your own hands

Tank preparation for repair includes a number of operations:

Draining fuel. There is a drain neck at the base of the gas tank; by twisting the lock plug from it, you can drain the fuel;
Washing the container. At home, caustic soda is used for washing, using it in the proportion - two glasses per 10 liters of warm water. The mixture is poured into the tank and infused for at least 5 minutes, after which the container is shaken and the liquid is drained. The procedure is repeated at least 3 times;
Drying. This operation must be carried out very carefully. It can be done naturally, but it will take a long time. It is better to use an industrial hair dryer, thus ensuring the effect of the air blowing under pressure.

During the washing of the container, you can find other problem areas of the surface that need to be corrected. After assessing the degree of damage, we determine the repair method:

Plastic gas tank 21099

When replacing the tank after repair, you should check all the equipment that comes with it. The integrity and suitability of the mesh of the fuel pump, float, cable is checked. Only after the entire fuel system has been checked, the gaskets and studs are in place, and no new leaks have been found, can the vehicle be used.
In cases of serious deformations, it is better not to tempt fate and replace the gas tank with a new one. It should be remembered that the fuel system is the basis for the safety and good technical condition of the vehicle. Therefore, entrust the repair of your vehicle to the specialists of official service centers.

The reasons for damage to fuel tanks can be different, in one case, rust, in the other a normal trip on Russian roads. A small blow and almost immediately we begin to smell the smell of gasoline in the cabin. The fuel level arrow also tells us that gasoline is leaking out. How difficult is it to fulfill repair the fuel tank yourself ?

If gas tank leaking, then it is not safe to drive with such a breakdown, so do not postpone its repair for a long time. Before starting work, it is recommended that you familiarize yourself with:

Hello everyone! My name is Mikhail, now I'll tell you a story about how I managed to exchange a dvenashka for a 2010 Camry. It all started with the fact that I was wildly annoyed by the breakdowns of the two, like nothing serious broke down, but the little things, damn it, so many things that really started to enrage. Here the idea was born that it was time to change the car to a foreign car. The choice fell on the tayet Camry of the tenths.

To drain gasoline from fuel tank, you will need to tilt the car with a jack to one side and use the tube. If the hole in the gas tank is in the lower part of it, then it will be faster to drain the gas through it. Then you should dry the gas tank from gasoline vapors.
Gas tank repair without removal or it is better to dismantle it, they decide depending on the accessibility to the place of damage and the type of repair work.

Do you know how they used to do repair of a fuel tank in the field our grandfathers? If a small crack appeared in the fuel tank, then the hole was rounded with a screwdriver. Next, we selected a bolt of a suitable size for this hole and tightened it, first we put rubber washers on it (from the wheel chamber).

If you look at the old 130th ZILs, you will notice that their tanks are completely pitted with bolts, which suggests that this method is quite reliable and durable. Currently, this method finds its favor among truckers, but we will analyze the most popular and affordable way to repair a gas tank for everyone:

This method at the moment remains the most popular for car enthusiasts. It is based on a material called "cold welding" that can be found in any home store. The meaning of this tool is that when the two components are mixed, the resulting plasticine-like mixture hardens after 10-30 minutes, which is ideal for patches.

If the damaged surface is first cleaned from dirt and dried, then repair by cold welding will be durable enough that you are unlikely to ever return to this damage. However, if you try to repair the hole in the gas tank without prior preparation, the treatment will be temporary.

This is probably the most high-quality gas tank repair... Before starting work, the tank is dismantled. If this is a gas tank 2110, then its removal / replacement is detailed in the repair instructions. If the fuel tank is seriously damaged, then a piece of the tank is cut out and a new one is welded in its place.

It is important if it means repairing the gas tank by welding, then filling the tank with water is a prerequisite. This method is applicable if the damage to the gas tank is minor. Now more and more often you can find services for the repair of fuel tanks with argon, but if you have a welding machine and skill, you can restore the gas tank on your own:

Repair of a plastic fuel tank has its own characteristics. For example, the cold welding method is unlikely to help here, because the plastic of the tank has poor adhesion. Soldering method is the only way, but pieces of the same plastic will be used as the solder, and the reinforcing material will be copper / metal mesh with a fine pitch.

The process is similar to repairing a bumper: We clean the surface to be treated. We cut out the mesh according to the shape of the damage and apply it to the places of damage. With a heated soldering iron, we melt the mesh into the plastic body.

In order to get rid of constant fines from cameras, many of our readers successfully use Special Nano Film for numbers. Legal and 100% reliable way to protect yourself from fines. Having familiarized ourselves and carefully studying this method, we decided to offer it to you as well.

In order to get rid of constant fines from cameras, many of our readers successfully use Special Nano Film for numbers. Legal and 100% reliable way to protect yourself from fines.Having familiarized ourselves and carefully studying this method, we decided to offer it to you as well.

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About five years ago, there was such a material - "Cold welding", we, with a friend, covered up his gas tank. Until I sold the car, I drove for a year, in the place where they used “cold welding” everything was dry.

Excerpts from the instruction:
“Description: Cold welding is an epoxy adhesive putty with a hardening addition of steel powder. Bonds metal, wood, ceramics, glass, plastic. Resistant to aggressive environments, retains its properties up to a temperature of 260 ° C. Waste-free and easy to use. The field of application of cold welding is quite wide: repair of gas tanks, radiators, mufflers, battery housings, crankcase trays, block heads, body and body parts, furniture, plumbing fixtures, cold welding of hot and cold water pipes, aquariums, tools, glass and mirrors, garden tools and much more. After hardening, turning, grinding, drilling, threading, and painting are allowed. It is possible to give the required shape. "

If the gas tank is leaking, then it is not safe to drive with such a breakdown, so do not postpone its repair for a long time. Before starting work, it is recommended that you familiarize yourself with:

General rules for repairing a gas tank

1. To drain the gasoline from the fuel tank, you will need to tilt the vehicle to one side and use a pipe.

2. Repair of a gas tank without removing it, or it is better to dismantle it, is decided depending on the availability to the place of damage and the type of repair work.

The popular way to repair a gas tank

Do you know how our grandfathers used to repair a fuel tank in the field? If a small crack appeared in the fuel tank, then the hole was rounded with a screwdriver. Next, we selected a bolt of a suitable size for this hole and tightened it, first we put rubber washers on it (from the wheel chamber).

A leak in a car's fuel tank can be sealed with glass cloth and epoxy glue. In this case, the reliability of the gluing site will be much higher than when using cold welding for gluing.