Metal gas tanks used in nearly every car, truck or motorcycle are highly susceptible to corrosion from within, created by condensation build-up within a partially empty tank. If left unchecked, the corrosion turns into rust that eventually eats through the tank's inner lining. New Jersey-based POR-15 offers a fuel tank restoration kit that removes light corrosion and coats the tank's liner with a sealant. Although the sealant cannot fix heavily rusted gas tanks, it can seal small pinhole leaks and will prevent future corrosion if applied properly.
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Things you need
- Service manual
- POR-15 Marine Clean solution
- Hot water
- POR-15 Metal Ready solution
- Blow dryer
- POR-15 tank sealant
Remove the gas tank from your car, truck or motorcycle and then drain the tank's contents into a suitable gas can. Refer to a service manual specific to the make and model of your vehicle for specific removal instructions.
Pour a mixture made from 1 quart of hot water and 1 quart of POR-15 Marine Clean solution into the tank's filler neck. Cover the filler with a strip of plastic from a heavy-duty trash bag and a rubber band. Turn the tank every two hours until the entire inner surface of the tank has been coated in the solution.
Remove the plastic strip and empty the Marine Clean and water solution from the tank. Rinse the inside of the tank with clean water and then fill the tank again with a fresh solution of Marine Clean and water. Rinse the tank thoroughly with fresh water after the inside of the tank has been completely coated with the second application of the solution.
Empty the entire bottle of the kit's Metal Ready solution into the gas tank. Reposition the tank every 30 minutes until the entire inner surface of the tank has been coated with the Metal Ready solution. Fill the tank with hot water, then empty and rinse the tank three to four times with hot water to ensure that the Metal Ready solution has been thoroughly removed. Dry out the inside of the gas tank with a blow dryer.
Pour the entire bottle of POR-15 tank sealer into the gas tank. Flip the tank over slowly to coat the entire inner surface of the tank with the sealer. Move the tank to a well-ventilated area and place the tank's filler neck over the sealer's can. Drain the remaining sealant into the can and then allow the sealant in the can and the tank to cure in place for at least 72 hours.
Reinstall the gas tank into your car, truck or motorcycle. Cover the sealant can after the sealant has cured completely, then discard the sealant.
Tips and warnings
- Light to moderate surface rust can be removed from the inside of the gas tank by pouring a cup of metal nuts into the tank prior to applying the kit's cleaning solutions. Shake the gas tank vigorously to loosen the rust, then pour the nuts out of the tank's filler neck and proceed as outlined above. The curing process can be shortened by blowing unheated air through the gas tank.
- Some of the chemicals included with the POR-15 fuel tank sealer kit can cause skin and eye irritations. Wear safety glasses and gloves at all times while working with this product. Don't cover the used sealant's can until it has fully cured. The sealant will release gases while curing that will cause a sealed can to burst.
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