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Bryan59EC 12-20-2011 12:07 PM

Plastic fuel tank repair
Some time ago, my 82 Dodge D-150 developed a pretty good sized leak.
Cannot fill the tank, or it will be leaking 'till it gets to 3/4.

As most of us know, most salvage yards destroy fuel tanks by poking a big hole in them while they process the car.

Today, I bought a tank from a yard that does not do this, but alas, it has a crack at the top. Not a big one, and most likely would not leak for a day until the fuel level dropped.

Pretty sure this small crack will put me in better shape than the tank currently in the truck.

Anybody here repair small cracks or holes in plastic tanks????
How is it done??
Is there some place I could take it for repair???

This is a larger tank than currently in the truck, not an easy job to pull.
Requires bed removal or rear end removal to get out. (Not really sure if there is enough room to slide it past the trans) I like the idea of a larger tank, but either way I need to get one of these repaired. Old Dodge pickups aren't growing on trees anymore, and I thought I was doing good just finding a decent tank.

dogwater 12-22-2011 07:36 PM

Fiberglass patch?Maybe a patch about twice as big of the crack.As long as theirs not flexing where the patch is.Sand area,clean with aectone then Home Depot fiberglass sheet & glue.I've seen duct tape & fiberglass glue used on gas tanks.

Flipper_1938 12-22-2011 07:49 PM

Plastic fuel tanks are made out of High Density Poly Etholene (spelling?). Not much will stick to it.

Only chance might be to re-melt the plastic with something like a sodering iron. ...But I don't think you will ever get the crack clean enough to not have contamination in your weld.

I'd find another tank.

Bryan59EC 12-22-2011 08:02 PM

Hard to find these things----are not reproduced.
Even the sending units are obsolete now.

But---I did have a major brain fart.
I just took it to the body shop (I spend a lot of time there), after I realized that Hector fixes bumpers all the time.

He had me clean the tank off, get my dremel, and clean out the crack and put a "V" in it.

He then warmed it up and "welded" it closed again.

The crack is (was) at the top on a factory seam, so when I get around to putting it in my truck (hoping existing brackets will work as this tank is larger), I will put some neoprene or some kind of rubber every place the tank comes into contact with the frame.

I probably would have never even noticed the tank was cracked, had I not tipped it on it's side and then saw it start seeping.

Next----on the hunt for a good sending unit.

tnovot 12-24-2011 06:38 PM

Although I have never used it on a gas tank, I have made successful repairs to a variety of plastics with JB Weld. It was recommended to me by a friend who owns a body shop to use the fast set formula athough I have also used the regular with good results.

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