How to Repair a Leaking Gas Tank

January 27, 2012

A leaky gas tank can not only cost you a lot of money in wasted fuel, it can be very dangerous and result in a potentially deadly fire or explosion. So, fixing a leaky gas tank needs to be done as soon as the leak is noticed. You can take it to a repair shop and spend a lot of money, or you can do it yourself and save yourself about $100. Here is a quick guide on how to easily repair a leaking gas tank on your vehicle.

What You Will Need

  • Gas tank repair epoxy putty compound
  • Car jack
  • Jack Stands
  • Sandpaper
  • Rubbing Alcohol or other degreaser
  • Clean towel or rag
  • Vinyl or kitchen gloves
  • Safety Glasses
  • Filtration mask

Step 1 - Jack up the Vehicle

Jack up the car to a height where you can place the jack stands underneath the vehicle. Once the jack stands are underneath the vehicle, lower the jack to a height so that the vehicle rest safely on the jack stands while you are working underneath the car.

Step 2 - Find the Leak or Hole in the Gas Tank

Crawl under the vehicle and inspect the gas tank. Find the area where the tank is leaking or where there is an obvious small hole where the gasoline drips or leaks out.

Step 3 - Sand the Leaky Area of the Tank

Use the sandpaper to sand the area where the tank is leaking. Sand an area approximately 1 1/2 inches to 2 inches in diameter surrounding the hole or leak in the gas tank.

Step 4 - Clean the Surface

Use the towel and alcohol, or other degreaser, to thoroughly clean the area that has been sanded. Make sure to remove any dirt, grease or grime that will prohibit the epoxy from being applied or curing correctly.

Step 5 - Mix the Epoxy

Follow the manufacturer's instructions for mixing the epoxy compound. You may have to mix the compound from two different tubes together for a couple of minutes and be sure to use it before it dries. Follow the instructions on the packet exactly for mixing the compound.

Step 6 - Shape and Apply the Epoxy

Next, cut off a piece of the compound that is about 1 to 1 1/2 inches long. Then shape the epoxy compound into a small cone shape with a tip at the top and a wider or broader base at the bottom.

Step 7 - Insert the Epoxy in the Hole

Once you have correctly shaped the epoxy compound into the shape of a cone, you will need to insert the tip of the cone shaped epoxy into the hole in the gas tank. Insert the epoxy compound as far as it will go into the hole and press and smooth the remaining compound into the area that has been sanded. You can use a couple of drops of water to make the smoothing process easier and help it blend better into the sanded material.

Step 8 - Fill the Tank with Gas

After the epoxy compound has dried and cured, you can fill your car's gas tank as you normally would. Once you fill the tank, make sure to check the tank again for leaks. However, if you have followed the directions above, the leak should now be sealed and the epoxy should hold for many years to come.

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