Melted gas tank? - Defender Source
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  #1  
Old June 29th, 2013, 01:53 PM
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Melted gas tank?

Took my fuel tank down recently and discovered it was partially deformed from heat. Has anyone else ever experienced this problem?
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  #2  
Old June 29th, 2013, 02:06 PM
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That sucks. Find a new one (very hard to get) and find out why. It is odd because your heat shield is still there. Did you have an exhaust leak?
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Old June 29th, 2013, 02:26 PM
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Good thoughts on the exhaust leak. It's possible. I'll double check. The tank's integrity isn't compromised from what I can tell. Ill keep an eye out for a new one.
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  #4  
Old June 29th, 2013, 02:46 PM
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WOW it would take a LOT of heat to do that.
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  #5  
Old June 29th, 2013, 04:41 PM
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Probably a result of the fire the previous owner never told you about...
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  #6  
Old June 29th, 2013, 05:15 PM
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Did a Jeep park to close behind you ?? Maybe it's an STD
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  #7  
Old June 29th, 2013, 09:50 PM
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STD is the only explanation that makes sense to me. No sign of fire anywhere else.
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  #8  
Old June 30th, 2013, 07:11 AM
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Are these tanks not (Almost) virtally the same as RoW Td5/TDCi 90 tanks?
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Old June 30th, 2013, 03:21 PM
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Has anyone ever thought about taking there original tank and having a company copy it in aluminum? I would think that would be a great idea
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  #10  
Old June 30th, 2013, 03:29 PM
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Quote:
Originally Posted by TDI Guy View Post
Has anyone ever thought about taking there original tank and having a company copy it in aluminum? I would think that would be a great idea
I keep wondering the same thing. Seems like some money to be made somewhere.
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Old June 30th, 2013, 03:49 PM
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Quote:
Originally Posted by diesel_jim View Post
Are these tanks not (Almost) virtally the same as RoW Td5/TDCi 90 tanks?
You would need to redo the fuel pump, but yes, you are right. Heaven forbid I have an issue, that is my plan to adapt a TD5 tank.
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  #12  
Old June 30th, 2013, 03:49 PM
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I believe there was a post about this, Kensington Motor Cars (KMC) was said to be doing this. I believe the guys name is Bill and there out of Las Vegas.
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Originally Posted by TDI Guy View Post
Has anyone ever thought about taking there original tank and having a company copy it in aluminum? I would think that would be a great idea
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  #13  
Old August 14th, 2013, 10:47 PM
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Reviving this thread that I had really hoped would be dead. After spending over 4 months restoring my D90 and after a short 2 mile test drive, my fuel tank started to leak.

I'm once again on the market for a replacement. Anyone know of someone willing to part with one?
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  #14  
Old August 14th, 2013, 10:51 PM
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CGalpin "welded" his tank. He had a decent size hole in it. Before throwing your tank out, check with him!!!
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  #15  
Old August 14th, 2013, 11:34 PM
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I followed CGalpin's advice and got a plastic welding kit. I got mine from Ebay (via eastwood). Although mine did not leak before, I knew I was close to getting into the tank. Only took like 200 miles of "I thought it was tight exhaust pipe" and I guess it wasn't and pushed through the asbestos/insulation shield. I will make and aluminum one to replace it. But here are a couple before and after pics.

The welding was pretty easy. The plastic melts really easy and spreads pretty easy. Be careful not to do too much depth at once. Take your time and do a couple layers. I was fighting some bubbles in the hot plastic from going too thick too fast.

Overall it was really easy, almost artwork like.

Photo 1 before, Photo 2 base layer with metal mesh, photo 3 second layer plastic (but like I said would have left for an hour to cool, and watched for bubbles in that period and smoothed with soldering iron if needed, might have also been a product of using acetone to clean the surface and it was evaporating thorough the molten plastic, not sure what the bubbling was for sure)

EDIT: Sorry I forgot how bubbled yours was. This might not be the fix, but that's what I did. Maybe if you find another tank you can donate yours to science and get something fab-ed up for the rest of the D90 community.
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