Fueling Fuel Tank on Car

Plastic Fuel Tank Repair: How To Repair

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There was once a time when most cars had their entire bodies made of indestructible iron and steel. But over time, many industries have begun to use plastic as a preferable option for producing some vehicle parts. So presently, fuel tanks found in many cars are made of plastic.

Compared with those made with steel or iron, plastic fuel tanks are longer-lasting, easy to maintain, easily installed, lightweight, corrosion-resistant, and wallet-friendly because they are made from refined crude oil.

Getting Started

On the downside, however, plastic fuel tanks are more likely to get cracked or break easily. When this happens, you may need to get a new tank or repair your plastic fuel tank.

Nevertheless, you do not have to fret because you will not be spending your entire life’s savings to repair a plastic fuel tank; it doesn’t cost that much.

You could get an automobile engineer to repair your plastic fuel tank, or you could attempt to fix it yourself. If you would like to repair your plastic fuel tank yourself, then simply follow any of these ways:

Method 1: Epoxy Glue Method

Of the three methods to repair a plastic fuel tank, this method is the easiest and least expensive. It also isn’t a permanent measure and should be used for really small punctures.

Materials Needed:

  • Fiberglass Patch
  • Sanding Paper
  • Shop Cloth
  • 2 Part Epoxy Glue
  • Alcohol


  1. Drain out completely any fuel that is left within the fuel tank.
  2. With the sand paper’s help, scratch the plastic fuel tank area you wish to repair.
  3. Clean up the area with a cloth containing alcohol.
  4. Mix the two-part Epoxy Glue and apply it around the edges of the puncture.
  5. Apply some of the Epoxy glue to the fiberglass and press the fiberglass on the punctured area.
  6. When the glue dries, you can add more sand to it and repaint it.
  7. Return the fuel to the plastic fuel tank.

Method 2: Seal With a Plastic Welder

Right now, you must think, really! Welding plastic?

Well, you heard it correctly. This method is a bit complex but can serve as a permanent solution to that plastic fuel tank you wish to repair.

Materials Needed:

  • A means of Protection like the helmet, Eye Gear, and welding Gloves
  • Specified Plastic Welder
  • Sandpaper
  • Plastic Welding, Rod


  1. Ret the right kind of welder
  2. Drain the fuel completely from your plastic tank.
  3. Heat the welding iron for about five minutes
  4. Put on your protective helmet and all other protective gear.
  5. With the plastic welder’s help, begin to fill the puncture from one end to the other.
  6. When the plastic dries, you can sand it and put the fuel back I’m the plastic tank.
Plastic Fuel Tank Repair

Method 3: Using a Soldering Gun

This method is quite simple, and we assure you it isn’t at all as complicated as you imagine. This method usually works best with gas cans.

Materials Needed:

  • A Soldering Gun
  • 2 Part Epoxy Glue
  • A Plastic Patch
  • A Sandpaper


  1. Wash the plastic fuel tank thoroughly after emptying it of the fuel it contained.
  2. Allow the plastic fuel tank to dry.
  3. Get a plastic made of high-density polyethylene, which is also chemically resistant to patch the hole. The plastic should be a bit bigger than the hole you wish to cover.
  4. With the sand paper’s aid, smoothen the fuel tank area that you wish to cover.
  5. Warm up your soldering gun.
  6. Dragging the soldering gun around the hole’s edges creates a round depression at the plastic fuel tank’s edge.
  7. Place the plastic patch on the soldered area.
  8. Mix the epoxy glue and cover the entire soldered cum plastic patched area.
  9. Allow the area to cool before smoothening it with sandpaper, and then you can spray and replace the fuel within the plastic fuel tank.

Tips for Repairing Plastic Fuel Tanks

There are safety tips to consider when repairing a plastic fuel tank. Any of the three methods of repairing a fuel tank can serve to protect your fuel from leaking away. They will also buy you ample time to save up for a new plastic fuel tank.

You should follow the drain-before-repair method. Ensure you have properly drained out the plastic fuel tank before you begin any repairs. This is because fuel and a plastic welder could cause sparks that may start up a fire. After repair, make sure you study the detailed tips on the best paints to use on your vehicle’s gas tank.  

Frequently Asked Questions

There are a few questions you must get familiar with as you plan to repair your plastic fuel tank. Let’s examine a few of them:

Q: Can a plastic fuel tank be repaired?

From our discussion so far, it is obvious that you can repair a fuel tank. However, it depends on the method you want to adopt. You must identify the material that matches the gas tank of your car.

For a simple DIY way, all you have to do is look for a plastic cover that will work for your gas tank. Cut the patch into a size bigger than the fuel tank crack you’re fixing. Make sure the plastic smoothens out and fuses together with the patch. To do this, place the cover on top of the crack before you weld them together.

Q: Will flex seal work on a plastic gas tank?

No, a flex seal cannot work on a gasoline tank that is made of plastic. You should not also use a flex seal on an oil tank or any other combustible material.

Final Thoughts

Now, you can boast of the best ways to get your plastic gasoline tank fixed without spending so much or causing further damage to the tank. One great benefit of using a plastic fuel tank from high-density polythene is that it prevents crash safety, saves space, and is malleable in a range of shapes.

Source: Carbibles.com

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