D90 gas tank hole fix - Defender Source
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  #1  
Old August 10th, 2008, 02:11 PM
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D90 gas tank hole fix

Well, I always wondered why my D90 had an odor of gas when the tank was full. The bonehead who owned it before drilled holes in the bed to put a bunch of stereo equipment. While prepping the bed for Rhino liner, I found that one of the drill holes goes into the top of the gas tank. Fortunately, the hole is less than 1cm in diameter. The tank costs over $900 on Rovers North and can't find one elsewhere listed (for now).

Anyone have any good ideas on how to safely patch this hole?

My initial thought was to drop the tank, empty it (b/c probably has dirt from the hole inside), replace the fuel filter and maybe the pump while it is down. Maybe use the fireproof caulk like you would use on the exhaust vent for gas water heaters and the like to patch the small hole?

Thanks in advance,

Heston
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  #2  
Old August 10th, 2008, 02:36 PM
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If you have the tank out and the hole is in the top, you could use an 8 or 10 mm bolt/nut/rubber washers
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  #3  
Old August 10th, 2008, 03:31 PM
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Thought about that but was worried that over time, the gasoline might break down the rubber washers? Maybe not -- just trying to get any and all input on the best seal with resistance to breakdown and fire hazards. Thanks much for the input and any follow-up thoughts.
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Old August 10th, 2008, 05:06 PM
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It's a non structural and non dependent portion of the tank, you just don't want it to leak or crack. The tanks are expensive. Eastwood Company sells plastic repair kits, but the good ones are expensive also.
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Old August 10th, 2008, 05:58 PM
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Use a blow torch and weld the plastic back together.
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  #6  
Old August 10th, 2008, 06:41 PM
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Quote:
Originally Posted by steinhnj
Use a blow torch and weld the plastic back together.
What he said.
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  #7  
Old August 10th, 2008, 06:55 PM
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JB weld perhaps?

Open flames around the tank are a big no-no unless you fill the tank with water to displace all the gas fumes. Those fumes don't just go poof, they go boom.
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  #8  
Old August 10th, 2008, 07:08 PM
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Marine-tex epoxy will survive no problem, Dad used it on the steel tank of a Chevy Blazer once, right in the middle of the bottom of the tank. Last I saw the truck it was 15 years later and the patch was still there.

-Hans
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  #9  
Old August 10th, 2008, 08:13 PM
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2X on Marine-Tex. Impervious to gas, diesel, solvents, etc.
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  #10  
Old August 10th, 2008, 08:39 PM
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POR 15 has some good repair kits, and some stuff for gas tanks as well...

http://www.por15.com/products.asp?dept=12
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  #11  
Old August 10th, 2008, 08:57 PM
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The POR 15 stuff is all for metal tanks BTW.
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  #12  
Old August 10th, 2008, 09:10 PM
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Quote:
Originally Posted by steinhnj
Use a blow torch and weld the plastic back together.
This was a joke by the way
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  #13  
Old August 10th, 2008, 09:13 PM
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Quote:
Originally Posted by steinhnj
This was a joke by the way
He can't answer you, he's at the Burn Unit!
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  #14  
Old August 10th, 2008, 09:33 PM
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I'd use the blow torch on the PO...
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  #15  
Old August 10th, 2008, 10:26 PM
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what you can use ...

How about some aviation type fuel tank sealer (aka PRC). It's a two part mix and holds very well and inexpensive. Combined with a plastic plug, your gas tank will be long gone before this plug ever fails.

My 02 cents.

Pat
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  #16  
Old August 10th, 2008, 11:27 PM
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Just use some black duct tape! just kidding...

Marine Tex is the best - it is made for this kind of task.... just prep the tank... scuff up the area where you are going to apply the epoxy with some sand paper - then hit it with some alcohol for a final cleaning before you apply. Good luck... How does the stereo sound... ?
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  #17  
Old August 11th, 2008, 09:46 AM
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Super seal all. Cheap can be found in auto parts stores and doesn't have any issues with gas or oil.
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  #18  
Old August 12th, 2008, 07:46 AM
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Thanks much for most of the replies! I started stocking up on Silvadene cream, gauze and bottles of saline until someone thankfully told me the blowtorch idea was indeed dicey. I think that I will go with the Marine tex fix. Off to West Marine...
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  #19  
Old August 12th, 2008, 12:36 PM
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I would cut a little piece of stainless steel in a circle, JB weld os similar it to the tank and secure with a few stainless sheet metal screws.
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  #20  
Old August 12th, 2008, 01:13 PM
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Definitely one of the funniest threads on this site in a while.
I had the same thing happen to mine and I used the plastic fuel tank repair stuff from Autozone 3 yrs ago. No problems since.
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