Chloe Zhang
Fiberglassing a plastic gas tank is a common solution to the problem of rusted-out fuel tanks. It is a cheap and easy method to repair tanks, and it also preserves the tank's original look. The process involves cutting fiberglass to fit the tank, covering the bottom and halfway up the sides, and then applying a thin coat of resin to these areas. After the resin dries, a heavy coat is applied, and the cloth is placed on top, removing any air bubbles and flattening it out. The cloth is then completely saturated with resin, and more coats are applied as needed. While this method is effective for gasoline tanks, it may not work for all types of fuel tanks, such as those used in motocross bikes, as the tank's flex may cause the fiberglass to delaminate over time.
How to Fiberglass a Plastic Gas Tank
| Characteristics | Values |
|---|---|
| Why Fiberglass a Gas Tank? | To restore the tank and keep it looking original |
| It is economical and easy to do | |
| Gasoline has no effect on fiberglass, and the tank will not rust again | |
| Materials | Fiberglass cloth |
| Resin with hardener | |
| Brush cleaner | |
| Cheap paintbrush | |
| Process | Cut the fiberglass cloth to fit the tank, covering the bottom and halfway up the sides |
| Mix a thin coat of resin and paint it onto the tank portions to be covered | |
| Allow the first coat to dry (time varies based on temperature and ventilation) | |
| Apply a heavy coat of resin, place the cloth on it, and work out air bubbles | |
| Saturate the cloth with more resin, ensuring it is thoroughly saturated and laying flat | |
| Apply additional coats as needed to achieve a smooth finish, allowing drying between coats | |
| Notes | The resin has a strong odor, so it is recommended to work outdoors or in a well-ventilated area |
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What You'll Learn
Cut fiberglass to fit the tank
To cut fiberglass to fit the tank, you will need to cut the cloth to cover the bottom and up the sides. On some tanks, you can cut the cloth in one piece by making cuts at the corners. On irregular and round tanks, you may need to cut one piece for the bottom and additional pieces for the sides. Overlap any cuts by about half an inch.
It is important to note that gasoline has no effect on fiberglass, and it is a common solution to repair rusted-out fuel tanks. Fiberglassing the tank will also help maintain its original appearance.
Before cutting the fiberglass, you will need to paint a thin coat of mixed resin on the portions of the tank that will be covered with the cloth. Allow this coat to dry, which can take as little as 30 minutes in warm outdoor conditions or several days inside a cool place.
Once the first coat is dry, apply a heavy coat of mixed resin and immediately place the cloth on top, working out any air bubbles and ensuring it lays flat. Completely saturate the cloth with more resin, using your fingers to work the cloth down.
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Prepare the resin
To prepare the resin, start by reading the mixing instructions that come with your chosen product, as different companies use different formulas. Remember, only mix the amount of resin that you will be able to use within 15 minutes, as once the resin hardener is mixed, it will set up hard and there is no way to keep unused resin from hardening.
After mixing, paint a thin coat of the resin on the portions of the fuel tank that will be covered with cloth. Set this aside and allow it to dry. The drying time will vary depending on the temperature and ventilation. On a warm day outside, it should dry within 30 minutes or less. However, inside a cool place, it may take several days.
Once the first coat has dried, apply a heavy coat of mixed resin. Immediately after, place the cloth on top, removing any air bubbles and ensuring it lays flat. Then, completely saturate the cloth with more resin, using your fingers to get the cloth to lay flat. You will likely have to use your fingers to work the cloth down. Be sure that the cloth is thoroughly saturated and laying flat.
After this second coat has dried, you can apply additional coats as needed, allowing the resin to dry between each application, until you achieve a smooth finish.
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Paint the tank with a thin coat of resin
To paint the tank with a thin coat of resin, start by mixing the resin. Different brands of resin have different formulas, so be sure to follow the mixing instructions on the packaging. Remember to only mix enough resin for the thin coat, as you will only have about 15 minutes to use it before it hardens.
Once you have mixed the resin, paint a thin coat onto the portions of the fuel tank that will be covered with cloth. Set the tank aside and allow the resin to dry. The drying time will vary depending on the temperature and ventilation—it may dry within 30 minutes if left outside on a warm day, but it could take several days if kept inside a cool place.
After the thin coat of resin has dried, you can move on to the next step of applying a heavy coat of resin and laying the cloth over it. But before you do that, be sure that this first coat has dried thoroughly, as you don't want to rush the process!
It is important to note that resin has a strong odour, so it is recommended to work in a well-ventilated area or outdoors if possible.
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Apply a heavy coat of resin and add the cloth
Once the cloth has been cut to size, the next step is to apply a heavy coat of resin and add the cloth. Before you begin, ensure you are in a well-ventilated area or working outside as the resin has a strong odour. Start by painting a thin coat of the mixed resin on the portions of the fuel tank that will be covered by the cloth. Allow this first coat to dry – this should take around 30 minutes outside on a warm day, but could take several days inside in a cool place.
After the first coat has dried, apply a heavy coat of mixed resin. Immediately place the cloth on top, working out any air bubbles and ensuring it lies flat. Then, before the resin dries, completely saturate the cloth with more resin. You will likely need to use your fingers to smooth out the cloth and ensure it is thoroughly saturated and lying flat.
Brush cleaner can be used to clean your hands after this step. It is important to note that once the resin and hardener are mixed, it will set up hard, so only mix enough resin for each step as you go.
After this second coat has dried, you can apply as many additional coats of resin as you feel are necessary to achieve a smooth finish, allowing the resin to dry between each coat.
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Finish with a final coat of resin
Once you have applied the fiberglass cloth to the tank, you will need to finish the job with a final coat of resin. This will ensure that the fiberglass is properly sealed and protected. Here is a step-by-step guide to completing the final coat of resin:
Before you begin, make sure you are working in a well-ventilated area as the resin has a strong odour. Also, ensure you are wearing suitable protective clothing, including gloves and a respirator.
First, mix the resin with a hardener. Follow the mixing directions provided with your chosen resin product, as different brands may have varying instructions. It is important to only mix a small amount at a time, enough for one coat, as the resin will begin to harden after mixing and cannot be stored.
Next, apply a thin coat of the mixed resin to the portions of the fuel tank covered by fiberglass cloth. Use a cheap paintbrush for this step, as the brush will be difficult to clean afterward. Allow this first coat to dry completely. Drying times will vary depending on temperature and ventilation; it may take as little as 30 minutes in warm, outdoor conditions, or several days if working inside in a cool environment.
Once the first coat is dry, apply a second, heavier coat of resin. Immediately lay the fiberglass cloth over the resin, smoothing out any air bubbles and ensuring the cloth is flat and fully saturated. You may need to use your fingers to work the cloth down, so be sure to have some brush cleaner on hand to remove resin from your skin.
Finally, apply as many additional coats of resin as you deem necessary to achieve a smooth finish, allowing each coat to dry completely before applying the next. Remember to work quickly, as the resin will begin to harden after mixing, and always follow the specific instructions provided with your chosen resin product.
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Frequently asked questions
Fiberglassing a plastic gas tank can restore it and prevent it from rusting again. It is also economical and easy to do.
You will need fiberglass cloth, resin (with hardener), brush cleaner, and a cheap paintbrush.
First, cut the fiberglass cloth to fit the tank, covering the bottom and halfway up the sides. Then, mix and apply a thin coat of resin to the portions of the tank that will be covered by the cloth. After the resin dries, apply a heavy coat of resin and immediately place the cloth on top, working out air bubbles. Completely saturate the cloth with resin. Once dry, apply additional coats of resin as needed, letting it dry between coats.
While it is possible to temporarily repair a cracked plastic gas tank with fiberglass, it is not recommended as a permanent solution. The tank may eventually delaminate as gasoline seeps through the cracks. A more permanent solution is to use a plastic welder to repair the crack.
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