Fuel Tank Leak, let me put the fear of GOD into you

[sclarke]

After my trip on the QB weekend i notice a slight fuel leak on Grommet the Zebra.
It was only dripping a small amount when i was in Warrigal on the way home, but after sitting for 2 weeks with a bucket under the drip it has filled it with about 3 litres

So today i went looking for the leak.
1st job was to drop the tank and split it from the tank guard.
The factory Tank is a nice design with lots of mastic or silicon to hold the tank to the guard. This when its not done properly in the factory, means dirt and water get in and start the rust process.

To seperate the tank from the guard i drilled the spot welds out, but only the guard part, not all the way thru the tank also.
Then a cold chisel and lots of complaining and grunting and the 2 were apart.

Then i got the wire brush out and cleaned all the loose rust and dirt off and found the following

The wet spots on the Left and Right sides and on bottom left is a Fuel leak due to rust.
https://www.aulro.com/afvb/images/imported/2009/01/1170.jpg

The rust and dirt still on the Tank Guard
https://www.aulro.com/afvb/images/imported/2007/06/124.jpg

I then got the rotory wire brush out and started cleaning it all up. 2 hours later and 1 sore lower back i had it cleaned up.

I then repaired the 3 leaks with 2 part epoxy that i use for Refrigeration. it is Oil resistant and sticks like shiet to a Bears Fur.
You can buy similar stuff from Autobarn and Repco

I then rust treated the Tank and guard.

https://www.aulro.com/afvb/images/imported/2009/01/1171.jpg
https://www.aulro.com/afvb/images/imported/2007/06/125.jpg

Next job is to put it back together and reseal the tank to the Guard. I will use silcon and lots of it.......

So is your tank about to leak??????
I never thought the rust would be that bad on this tank, but i guess its a common place as the guard and tank are not sealed correctly in the factory.

Clarkie

[spudboy]

Did the same job on a friend's 300TDi a few weeks ago. Little stones got in between the tank and the fuel tank guard and abraded their way through the tank. We fitted a new tank as it was leaking from about 3 places. Just tiny weeps, not full on holes, but overnight it would drip half a litre or so.

Messy job to replace it once all the diesel and dust coagulate into a black grime. Completely ruined a good pair of overalls!

We also broke the (brittle) plastic connector on the fuel uptake pipe. This let air into the line and it ran VERY badly until we glued up the connector. Took 2 - 3 hour to find out where the problem was though.

[JDNSW]

Been there done that! - but I replaced the tank after finding all the baffles had broken off and were rattling round loose in the tank.

John

[ladas]

After my trip on the QB weekend i notice a slight fuel leak on Grommet the Zebra.
It was only dripping a small amount when i was in Warrigal on the way home, but after sitting for 2 weeks with a bucket under the drip it has filled it with about 3 litres

So today i went looking for the leak.
1st job was to drop the tank and split it from the tank guard.
The factory Tank is a nice design with lots of mastic or silicon to hold the tank to the guard. This when its not done properly in the factory, means dirt and water get in and start the rust process.

To seperate the tank from the guard i drilled the spot welds out, but only the guard part, not all the way thru the tank also.
Then a cold chisel and lots of complaining and grunting and the 2 were apart.

Then i got the wire brush out and cleaned all the loose rust and dirt off and found the following

The wet spots on the Left and Right sides and on bottom left is a Fuel leak due to rust.


The rust and dirt still on the Tank Guard


I then got the rotory wire brush out and started cleaning it all up. 2 hours later and 1 sore lower back i had it cleaned up.

I then repaired the 3 leaks with 2 part epoxy that i use for Refrigeration. it is Oil resistant and sticks like shiet to a Bears Fur.
You can buy similar stuff from Autobarn and Repco

I then rust treated the Tank and guard.

Next job is to put it back together and reseal the tank to the Guard. I will use silcon and lots of it.......

So is your tank about to leak??????
I never thought the rust would be that bad on this tank, but i guess its a common place as the guard and tank are not sealed correctly in the factory.

Clarkie

Nice Job Mr. Clarke

[rick130]

had to perform the same job back at Christmas Clarkie, and used the good old Epox-A-Leak too :D

[sclarke]

had to perform the same job back at Christmas Clarkie, and used the good old Epox-A-Leak too :D

Yep Epox-A-Leak is great. i have some stuff that you mix and heat, but i dont have a heat gun and i'm not keen on a glowing element near a fuel tank.

Last time i priced a tank the Wreckers wanted about $400-$500 so fixing it was the better option.



QUESTION
The Fuel pick up connector has a "O" Ring, does it go on the pick up pipe 1st or the tank fuel sender???

Clarkie

[mox]

A solution to a damaged or leaking fuel tank I have seen on a Defender 130 with tray similar to mine: Note it had Queensland number plates on it. Also probably from Qld was a tap in the side type 18 gallon beer keg for a fuel tank. I gather made of stainless steel so would not rust.

Maybe this is worth remembering, even if only for emergency fuel tank replacement while in the back blocks.