Plastic Fuel Tank Repair Procedures

Updated February 21, 2017

Plastic fuel tanks can be found on a variety of both small and large vehicles. Boats, lawnmowers and generators have plastic fuel tanks due to their lightweight, and strength. Even so, sometimes plastic tanks get cracks in them, causing fuel loss and a danger to anyone near it. Plastic tanks are cheap, but when they break, sometimes you cannot find the exact one you need at the moment when you need it. When a plastic fuel tank cannot be replaced, they are fairly simple to repair. This article outlines the method to use when fixing a plastic fuel tank.

Empty and Wash

Make sure the fuel tank is completely empty and washed out thoroughly before attempting a repair. The use of heat on the plastic tank could cause any fuel to combust, which is a major hazard.

Cut the plastic

Cut several pieces of heavy plastic from a similar material to patch your tanks. Depending on the size of the hole, a small or large amount may be needed. Use a heat gun to make the plastic malleable. You do not want it completely melted, but you do want the plastic quite sticky.

Patch your tank

Heat the edges of the hole in your plastic tank so that they will take the plastic patches you have created. Take some tweezers to lift your heated patches and place it on the heated section of your hole. Depending on the size of the patch and the hole, you may need to do one section at a time. Once the patch is in place, use a hot putty knife to smooth out the patch. Any bulges could become weak with time.

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