Fixing a Plastic Gas Tank on a Car: Why Replacement is Often the Best Option
When it comes to fixing a plastic gas tank on a car, many are tempted by the idea of saving money by repairing it. However, the reality is that repairing a plastic gas tank can often be a waste of time and resources. Here, we explore why a replacement is usually the better choice and provide guidance on how to properly replace a plastic gas tank.
Why Repairing a Plastic Gas Tank is Not Worth It
Fixing a plastic gas tank with epoxy or another adhesive compound is a temporary solution at best. Over time, the gas in the tank can degrade the adhesive, rendering the repair ineffective. For example, I've seen firsthand how adhesives used on plastic structures under the hood, such as windshield washer reservoirs, can fail within months.
Examples of Failing Adhesives
I once used an adhesive on a boat gas can and a motorcycle gas tank, and both eventually failed. In another instance, I repaired a plastic gas tank under a car's hood using epoxy, but after only three months, the reservoir was leaking worse than before. Liquids such as gas can find the easiest routes to leak, and once this happens, the repair is often ineffective.
Long-Term Solution: Replace the Gas Tank
The best long-term solution is to replace the gas tank. While the initial cost of a replacement can be seen as a drawback, it is generally more cost-effective in the long run. Repair materials can degrade over time, and leaks can become more severe, making the cost of repairs escalate.
Proper Replacement of a Plastic Gas Tank
If you need to replace a plastic gas tank, follow these steps to ensure a safe and effective installation:
Preparation
Empty any gas into another appropriate container to avoid contamination.
Leave the cap off the plastic gas tank to allow any residual gas to evaporate.
Disposal
Toss the plastic gas tank into the recycle bin if allowed in your area.
Installation
Buy a new plastic gas tank that matches your vehicle's specifications.
Ensure that you get the right size and type of gas tank for your car. Consult your vehicle's manual or a professional if necessary.
Position the new gas tank in the correct location and secure it with the mounting bolts.
Connect the gas lines and fuel pump to the new gas tank.
Check for any leaks and make necessary adjustments.
Replacing a Gas Tank with Epoxy
If you still want to try repairing a gas tank with epoxy, or you are in a situation where replacing the tank is not an option, you can attempt a repair. However, it is important to approach this with caution and proper techniques.
Repairing a Gas Tank with Epoxy
Empty any gas into another appropriate container.
Leave the cap off the plastic gas tank to allow any residual gas to evaporate.
Toss the plastic gas tank into the recycle bin if allowed in your area.
Buy a new plastic gas tank that matches the original.
Prepare the repair area by sanding the crack or break with 80-grit sandpaper, just enough to remove the shine from the tank.
Apply epoxy to the repair area, ensuring a uniform coverage. For larger breaks, use woven fiberglass boat cloth, minimum of 2 or 3 layers, soaked in epoxy.
Allow the tank to sit for a day to ensure proper curing. If done correctly, the repair should be as good as new.
Conclusion
While repairing a plastic gas tank with epoxy can be attempted, it is generally not a recommended long-term solution. Replacing the gas tank is often the best choice due to the potential risks and the guaranteed longevity of a new tank. Always prioritize safety when working with fuel systems, and consult a professional if you are unsure about any part of the process.