Ethan Clarke
Plastic gas tanks are notoriously difficult to repair, with many people opting to replace them instead. However, this can be costly, so some people have experimented with different ways to patch a plastic gas tank. The type of plastic the tank is made of will determine the best method for repairing it. Common plastics used for gas tanks include polyethylene and polypropylene, and HDPE, which is used for plastic gas tanks most of the time.
How to patch a plastic gas tank
| Characteristics | Values |
|---|---|
| Plastic type | Polypropylene, Polyethylene, High-Density Polyethylene (HDPE) |
| Repair methods | Soldering iron, Plastic welding, Epoxy glue, Plastic weld glue, Magic goo, O-ring sealing surface, Plastic filler, Clay |
| Tools | Soldering iron, Solder gun, Hot air welder, Holt melt glue gun, Heat gun |
| Preparation | Clean with alcohol or lacquer thinner, Roughen with file or sandpaper, Drill holes to prevent crack from spreading |
| Cost | $25 for weld glue repair, $45 for repair kit, $50-$75 for a new tank |
| Time | 1 week for weld glue repair |
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What You'll Learn
Soldering iron to melt crack together
Before attempting to repair a plastic gas tank, it is important to identify the type of plastic it is made of. Some plastics can be patched with different types of goop, while others cannot and need specific procedures. Most plastic gas tanks are made of HDPE, which is challenging to glue.
If you are looking to repair a crack in your plastic gas tank, one method is to use a soldering iron to melt the crack together. Here is a step-by-step guide on how to do this:
- Ensure the gas tank is empty and clean. It is important to remove any fuel residue or contaminants from the surface to be repaired. You can use alcohol to clean the plastic.
- If the crack is large, you may want to drill a small hole at both ends of the crack to prevent it from spreading further.
- Get a decent-sized soldering iron and turn it on. Adjust the temperature to a low setting to start, as you will need to gradually increase the heat to avoid scorching the plastic.
- Hold the two pieces of plastic together and push them firmly along the crack.
- While holding the pieces together, run the soldering iron tip along the crack until the plastic begins to melt and the pieces become partially welded together.
- Adjust the position of the plastic pieces while they are still hot and movable to ensure they fit together as closely as possible.
- Strengthen the weld by adding small pieces of plastic, such as thin strips, along the seam. You can use plastic from a compatible source, such as a milk jug or a plastic welding rod.
- Fully melt the added plastic pieces by pressing them with the soldering iron tip until they liquefy. Smoothly distribute the liquefied plastic along the length of the seam.
- Finally, go over the repaired area and the surrounding plastic with swift, smooth strokes of the soldering iron to ensure an even and smooth finish.
With this method, you can create a strong and durable repair on your plastic gas tank. However, it is important to note that the repaired area may not look exactly the same as the original plastic, and it may require some practice to perfect the technique.
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Plastic welding with a soldering iron
To weld plastic with a soldering iron, the plastic needs to be melted. This can be achieved by using a soldering iron with a temperature of around 210-230 degrees Celsius. It is important to start at a lower temperature and gradually increase the heat to avoid burning the plastic. The soldering iron should be moved quickly along the weld area to prevent scorching the plastic. Additionally, the weld area can be preheated with a heat gun to keep the plastic in a molten state for longer, allowing for better flow and fusion.
During the welding process, plastic filler or welding rods made from the same type of plastic as the gas tank can be used to fill in gaps or cracks. These fillers come in the form of filaments or strips and are melted into the weld seam. It is important to ensure that the gas tank is clean and free of any fuel residue before welding. This can be achieved by using a solvent to clean the area and swirling water inside the tank until the fuel smell dissipates.
After welding, the repaired area should be stronger than before and capable of withstanding the stresses that caused the initial damage. However, it is important to note that plastic welding may not always result in a permanent fix, and cracks may reappear or occur elsewhere. Therefore, it is recommended to cover the weld with a fiberglass cloth and plastic bonder epoxy for added strength and protection.
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Using clay to fill holes
Before attempting to repair a hole in a plastic gas tank, it is important to identify the type of plastic the tank is made of. Some plastics can be patched with different types of goop, while others need specific procedures. Most plastic gas tanks are made of HDPE, which is challenging to glue.
If you know the type of plastic, you can buy the correct plastic welding rod to fill in the hole. Start by draining the tank and letting it dry completely. Sand the area around the hole so that the adhesive compound can adhere properly. Then, use a heat gun to expand and unlink the plastic molecules. Apply the plastic welding rod at 5-10 psi and let it cool, allowing the molecules to link back up and fuse together.
You can also use clay to fill holes in a plastic gas tank. Look for clay in a round tube that is labelled gas-proof and suitable for use underwater and with battery acid. Clean the tank with a lacquer thinner and roughen the surface with 36-grit sandpaper or a file. Then, clean the tank again and apply the clay by kneading it into a cone shape and pushing it into the hole. Flatten any excess clay.
Another option is to use epoxy glue and a fiberglass patch. Drain the tank and let it dry, then sand the area around the hole and clean it with a cloth soaked in rubbing alcohol. Mix the epoxy glue, apply it over the hole, and press the fiberglass patch into the epoxy. Allow the epoxy to dry, then sand any bumps and spray paint the area if desired.
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Using an O-ring sealing surface
Firstly, identify the type of plastic your gas tank is made of. If it is polypropylene, you can use an O-ring sealing surface to fix it. If it is another type of plastic, such as High-Density Polyethylene (HDPE), you can use a hot air welder to fix it if you can get some compatible plastic for the patch.
If you are using an O-ring sealing surface, you will need to create a plug with an O-ring sealing surface. This can be done by using a rubber O-ring that is compatible with exposure to gasoline, such as one made of neoprene. The O-ring should be mechanically compressed between an exterior flat cap made of a durable material such as 3/16" steel, with a 6 or 8 hole bolt circle for the outside. Place the cap and run up SHCS screws to draw the cap and ring up snug to the outside of the tank. If you want to be extra cautious, you can put a bead of silicone rubber on the cap before you draw up the ring.
If you are fixing a hole that was drilled to drain gas, you may need to use a thicker plug so that the plug can get a few turns and you have plenty of material to compress. You can also use epoxy or another type of sealant as a thread sealer.
It is important to note that this method may not provide a permanent solution, and it is always recommended to seek professional help if you are unsure about how to fix your plastic gas tank.
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Using a plastic welding kit
Plastic welding kits are available at hardware stores, auto parts stores, and online retailers. These kits typically include a heat gun and plastic welding rods. Before beginning the repair, ensure that you are working in a well-ventilated area and that the gas tank is empty and clean. It is important to note that different plastics have different melting points, so it is crucial to identify the type of plastic your gas tank is made of and select the appropriate welding rod. Polyethylene, for example, is commonly used in gas tanks and requires a specific type of welding rod.
Once you have the necessary equipment and have identified the plastic type, you can begin the repair process. Start by removing the gas tank from the vehicle and setting it up in a secure welding area. Clean the area around the hole or crack with a solvent, and if necessary, use sandpaper to smooth the surface. This will ensure that the weld adheres properly to the plastic. Next, heat up the plastic welding gun and apply the welding rod to the damaged area. The welding rod should be of a similar type of plastic as the gas tank to ensure compatibility and a strong bond.
As the plastic begins to melt, use the welding gun to push the melted plastic into the hole or crack, filling it as much as possible. Continue applying the welding rod and use the gun to smooth out the plastic, creating a flat surface. Allow the welded area to cool and harden. Once it has cooled, you can use a soldering iron to melt the edges of the repaired area, creating a trench. This will help to further seal the repair and ensure a strong bond.
After the trench has been created, lay a plastic patch over the repaired area. The patch should be made of similar material as the gas tank and slightly larger than the repaired area. Use the soldering iron to fuse the patch to the welded area, creating a strong bond. Allow the patch to cool and dry completely before reinstalling the gas tank. It is important to note that plastic welding requires practice and precision. Take your time and follow the instructions provided with your plastic welding kit for the best results.
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Frequently asked questions
The best method to patch a plastic gas tank depends on the type of plastic it is made of. Some types of plastic gas tanks can be patched with goop or glue, while others can be welded.
Some types of plastic gas tanks can be patched with a two-part epoxy glue, or a high-strength plastic weld glue. However, it is important to note that glues may fail and are not recommended for certain types of plastics, such as polyethylene and polypropylene.
Plastic gas tanks can be welded using a soldering iron or a hot air welder. It is important to clean the plastic and reach a temperature of 500 degrees Fahrenheit for the molecules inside the plastic to expand and become unlinked.
Some alternative methods to patch a plastic gas tank include using a plastic welding kit, a clay-type material made for repairing gas tanks, or an O-ring sealing surface.
