Can a dented fuel tank be repaired?

[CN Spots]

I have a old outboard that I have been restoring all summer that has a pretty dinged up aluminum fuel tank. It also had some holes due to corrosion. This tank forms the top of the motor so I would like to have it smooth even if I never put gas in it. (It has an aux. feed) I've tried to fix it with JB weld and Bondo praying that it won't pop off but now some small bumps are showing up in a few spots that will probably require repainting. Dang. DId I do something wrong? Thanks.<br /><br />'figured I'd put this in the Boat Restoration topic first since we're technically dealing with aluminum repair.

 

[klos]

Re: Can a dented fuel tank be repaired?

I don't know how well it would work with this tank, but with automotive fuel tanks I have put rubber expantion pluges in the filler neck & fittings. Then blow compressed air into the tank to pop out the dents. Just keep the plugs pointed away from your face.

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

Most of these dents are about the size of a golf ball or smaller and any repair done to the inside would have to go through the filler hole which is about the size of a quarter. Even if I could pop or hammer them out there would still be some type of smoothing necessary. This tank is only about a gallon and a half and it would probably explode before air pressure could pop any dents. -BUt thanks for the tip.

 

[joblo33]

Re: Can a dented fuel tank be repaired?

Bring it to a radiator shop and have it leak proofed with that stuff they pour inside, then use something like bondo on the dents.<br />Eric

 

[Buttanic]

Re: Can a dented fuel tank be repaired?

A good auto body repairman should be able to pull the dents out.

 

[Mark42]

Re: Can a dented fuel tank be repaired?

You can try epoxying an eye to the dent then use a rod through the eye to pry the dent up, or use a weight (like 5lb sledge) attached to the eye with a length of wire and pull dent out by slamming the wire tight. When done pulling the dents, cut the eye bolts off and grind down stub to tank. Both are a form of poor mans dent puller without drilling holes in the tank.

 

[Wimperdink]

Re: Can a dented fuel tank be repaired?

Pops-a-dent <br />.<br />.<br />.<br />.<br />.<br />.<br />.<br />YES I'M KIDDING! lol hope I at least got an inside reaction from some of ya.

 

[Chris1956]

Re: Can a dented fuel tank be repaired?

CN, I have used marine-tex in conjunction with glass cloth to repair my steel fuel tank. It works pretty well. Make sure the aluminum is good and clean (22grit sandpaper + acetone), smear the marine-tex onto the cloth, apply to the holy area, and smooth more marine-tex over the cloth. For the non-holy areas you can use marine surfacing (polyester) putty. Use some zinc-chromate primer and paint 'er up!

 

[PuddleJumper]

Re: Can a dented fuel tank be repaired?

Don't laugh--- I know a guy who pulled some dents out of a motorcycle gas tank with one of those dent pullers u see advertised on TV that has 3 cups w/the middle one glued to dent and pull out by a screww pull mechanism.

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

I'll try the marine surfacing putty next time instead of bondo (thanks Chris). The combo of JB weld and Bondo might be what's causing the bumps to form. I couldn't find any 22 grit sandpaper... guess I'll just rub it with a rock. lol.<br /><br />Iappreciate everyone's help on this one.

 

[KilroyJC]

Re: Can a dented fuel tank be repaired?

What kind of motor? make/model/year?<br /><br />Have you considered just replacing the tank completely? It's not like the tank is a serial-numbered part, after all. Between eBay & the crowd here (have you seen chinewalker's site? http://www.pfs-ware.com/smith ) you should be able to get something solid...

 

[Chris1956]

Re: Can a dented fuel tank be repaired?

CN, I really meant 220 grit paper. Don't want to scratch it up with course paper. <br /><br />Bondo is similar to marine putty, however not as water proof due to its talc base. <br /><br />I found the combo of the epoxy putty (Marine-tex) and the glass cloth really helps put a consistant layer of putty on the object to be repaired, and adds immensly to the strength of the repair. Good luck

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

It's a '57 Elgin 7.5hp model#571 58782. You're right Kilroy, there are a ton of these on ebay but most have the same battle scars as mine or worse. It's restoration is somewhat of a self-challange for me. I've always been afraid to work on outboards due to my ignorance of their inner workings, other than a carb rebuild, I left them alone. I came across this one from a friend and he didn't care what I did to it or if he even got it back. I think Elgins are a good choice for this because they're very simple, plentiful and not that desirable in a collection. Unlike a Merc Mark 20 or something. Not to mention this thing had been painted with a roller and stuffed in a barn during the Carter administration where it became a dirt-dobber housing project. They built nests clear to the reed valves! Anyway, it has been completely disassembled, stripped, primed and painted (in black red an silver, I hate turquoise) and is almost ready to fire, sans the tank problem which will probably require me to REstrip and REpaint it. <br /><br />Ever notice how adding "RE" to a verb costs you a whole lot of time and money?<br /><br />Chris- I knew what you ment, I was just poking fun. I find the thought of a piece of paper with a handful of gravel glued to it rather amusing.<br /><br />Thanks again guys

 

[KilroyJC]

Re: Can a dented fuel tank be repaired?

Hello again - <br /><br /><br />If you know anyone who is really good with a TIG-welder, maybe getting one of those other battle-scarred tanks - with the scars in different places - to cut up for patch panels woul be a viable option. After all, the contours are already stamped in, and you'd just have to fit and weld. Just like patch panels for classic cars.<br /><br />Please post pics! Before & after - it's fun to watch other people's projects!<br /><br />Matt M

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

Maaaaan, if I knew a guy with a TIG welder, he'd be my best friend! And I'd keep him busy! Unfortnately those guys are kinda sparse (and pricy) Got my eye on a pile of Elgin parts on ebay right now which includes a tank but like most ebay images, I can't tell how banged up it is. I gave up on asking sellers "is it in good shape" as the term"good" tends to vary from person to person. If I buy it and it's in better shape than mine, I'll use it. <br /><br />I'd like to post a few pics but I'm not quite sure how.

 

[KilroyJC]

Re: Can a dented fuel tank be repaired?

Time to start hanging around with the local hot-rodders... Hopefully this weekend I'm going to get to take my boat to a welding shop whose owner is friends with a friend of a guy tht a friend of mine knows---you get the idea!<br /><br />I'm not saying that it'll be free, or even cheap, but it comes with a recommendation, which is more than half the battle, in my book.<br /><br />If I'm not mistaken there's something in the FAQ's about posting pics, or just use the red <Search> button for "post pictures" & see what comes up.<br /><br />I just link to my freebie website that I made for putting up pics relating to topics I'm on in this forum:<br /><br /> http://mysite.verizon.net/kilroyjc <br /><br />(shameless plug!)<br /><br />Good Luck!<br /><br />Matt

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

Well, I won the tank and some other Elgin nick knacks the seller had for 12 bucks plus shipping. I'll clean up what I don't need and resell it. Can't wait to see what the tank looks like.<br /><br />I'm still working on the pic posting thing. It might take me a minute, but I'll figure it out.<br /><br />Maybe.<br /><br />spots

 

[CN Spots]

Re: Can a dented fuel tank be repaired?

The stuff came in today and the "new" tank is in considerably better shape than mine was. I also scored two lower end units w/props, two front shrouds, two spark plug covers,2 recoils, 2 complete carbs and a bunch of other stuff for a total of 35 dollars.<br /><br />Ebay rocks.<br /><br />spots

 

[KilroyJC]

Re: Can a dented fuel tank be repaired?

EXCELLENT!!!!<br />GREAT SCORE!!!!<br /><br />Fix it up and post pics!<br /><br />Just got an Evinrude control unit with electrical cable for 20 bucks + 9.00 shipping. It's beat up, but I just wanted it for parts, anyway.<br /><br />Gotta love eBay!