Hole in the Fuel Tank - how to repair?

Discussion in 'The Garage' started by JNRobert, Jan 31, 2011.

  1. JNRobert

    JNRobert Breaking Wind

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    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)

    :ear
    #1
  2. ivantheterrible

    ivantheterrible Been here awhile

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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!
    #2
  3. JNRobert

    JNRobert Breaking Wind

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    No rust. Accidentally punched a hole with a sharp object. It's small and no other damage and its a new tank. :bluduh
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  4. Speedo66

    Speedo66 Transient

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  5. fast4d

    fast4d Long timer

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    tank is steel, alum or plastic?
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  6. JNRobert

    JNRobert Breaking Wind

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    Steel
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  7. JNRobert

    JNRobert Breaking Wind

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  8. RVDan

    RVDan Long timer

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    [​IMG]
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  9. JNRobert

    JNRobert Breaking Wind

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    RVDan, does Seal All work - have you used it?
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  10. Beezer

    Beezer Long timer

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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.
    #10
  11. LuciferMutt

    LuciferMutt Rides slow bike slow

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    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.
    #11
  12. Mista Vern

    Mista Vern Knows all - tells some.

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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.
    #12
  13. TheOtherBart

    TheOtherBart Long timer

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    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.
    #13
  14. stainlesscycle

    stainlesscycle Long timer

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    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.
    #14
  15. 2speed

    2speed Puching adventurer

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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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  16. stainlesscycle

    stainlesscycle Long timer

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    there is no doubt about that. solder/braze is the only permanent method (until the area around your repair rusts out - which it will eventually...)
    #16
  17. fast4d

    fast4d Long timer

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    I agree. other than fuel a motorcycle tank will endure alot of vibrations.
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  18. bayoulubejim

    bayoulubejim Banned

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    Clean the tank first, then drop in some dry ice before you braze or weld.

    Your wife will thank me.
    #18
  19. LuciferMutt

    LuciferMutt Rides slow bike slow

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    Does the gas from the dry ice cancel out the fuel fumes or something?
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  20. Anorak

    Anorak Woolf Barnato

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    Call Norman Racing in Berkeley and ask for Dennis. He's an amazing welder and does tanks all the time.
    #20