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Old 07-13-2018, 06:35 PM   #1
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Weld auto gas tank


Greetings.


I have a 1993 Toyota RV, a Toyota 6 cyl pickup with a camper on the back. My OE gas tank is in poor condition on the inside.


I purchased an aftermarket replacement tank and there seems to be lots of problems with the aftermarket tanks. There is a baffle spot welded on the inside and the spot welds are braking on the bottom and causing the tanks to leak.


Returning the tank is not an option and there does not seem to be any reliable aftermarket tanks available, only new from the dealer for $400.



So I am curious about having the spotwelds rewelded before installing tank. Mine is still a new unused tank.



Any input on this would be greatly appreciated. I have included a photo of a similar tank with broken spotwelds leaking.
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Old 07-13-2018, 10:32 PM   #2
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Re: Weld auto gas tank


If it has never had any fuel in it, any decent welder can repair the bad welds, Gas and mild steel rod, braising, even a mig welder, will work.

But if there ever has been gasoline in it, it is a bomb in the waiting, even one small drop of gasoline hanging around in there will ignite and do major damage to anything within 20 feet of it, that is something not to mess with.

Call a few welders, and ask if they are willing to do this, explain that there has never been any fuel present, and keep trying.

Long ago I had to resort to a rubber gasket and a metal screw , screwed into a hole to get me back to town , and a place to buy another tank from a tow yard.

That might be an option, but trusting a screw to not vibrate loose is risky.


ED
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Old 07-14-2018, 05:43 AM   #3
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Re: Weld auto gas tank


I've brazed up several old gas tanks over the years. What I always did after draining the gas was to fill the tank with water. Depending on what/where I needed to braze determined if I left the water in it. Once done I'd slosh some denatured alcohol around in the tank to help remove any leftover water .... and then add dry gas to the first tank of fuel.
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Old 07-14-2018, 07:46 AM   #4
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Re: Weld auto gas tank


In college welding class, we took used tanks and cut holes in the tank and welded patches to cover the holes. Our process was
1. remove tank from car, and clean exterior of tank
2. remove tank sender
3. Using an exhaust hose, connect to running engine and then run hose to tank to be worked on
4. after 1/2 hour, heat tank with large tip, pass large tip over sender hole. Any fuel in the tank will off-gas and will burn when the large tip is passed over sender hole. Run the large tip over the tank again. Any solder will be blown off, any patches will come off. Fill holes, use patches as needed. Fill with water, look for more leaks.
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Old 07-14-2018, 07:56 AM   #5
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Re: Weld auto gas tank


Here is a way to fix it even if it had gas in it. There is an iron rod with a handle & a thick piece of iron on it at the opposite end. I don't know what it's called. You heat the piece of iron with a torch & press the solder between the iron & the tank. Since gas only ignites by a flame or a spark, it won't explode.
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Old 07-14-2018, 07:58 AM   #6
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Re: Weld auto gas tank


I found it.


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Old 07-14-2018, 10:13 AM   #7
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Re: Weld auto gas tank


That is a way old soldering iron, heated in a blacksmith forge.

Adequate, for the job.


ED
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Old 07-14-2018, 10:19 AM   #8
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Re: Weld auto gas tank


I have soldered brass shim stock over a fair size hole.
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Old 07-14-2018, 10:33 AM   #9
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Re: Weld auto gas tank


Quote:
Originally Posted by Guap0_ View Post
I found it.




We still use these in our shop for hvac safety pans. We buy most of them but if we need a custom one we use it to solder the corners and nipples. Y’all are making me feel old lol


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Old 07-14-2018, 10:45 AM   #10
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Re: Weld auto gas tank


I am old enough to remember soldering gas tanks with a blow torch and soldering iorn! Was common a long time ago. There was a hook on top of the torch, put the iron in it and the iron would be in the flame.



Was not sure on the welding, with the thin metals and some odd stuff on the market today, like galvalume. The only thing I am sure of with this tank is it is not plastic.



I have also thought about having someone redo the spot welds and then soldering a patch over it??


I was taught soldering in high school, likely have an app for it now
Thanks for the responses always greatly appreciated.
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Old 07-14-2018, 11:00 AM   #11
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Re: Weld auto gas tank


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Old 07-14-2018, 12:51 PM   #12
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Re: Weld auto gas tank


Running exhaust through the tank before welding is a very old trick, I recall doing it back in the 70s.
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Old 07-14-2018, 03:31 PM   #13
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Re: Weld auto gas tank


Quote:
The only thing I am sure of with this tank is it is not plastic.
You'll be the first to know when you put heat to it.
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Old 07-14-2018, 04:15 PM   #14
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Re: Weld auto gas tank


Quote:
Originally Posted by Guap0_ View Post
You'll be the first to know when you put heat to it.

Unless it is some new plastic, I am 100% sure it is metal.


Guap0???? PI's ??
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Old 07-14-2018, 06:46 PM   #15
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Re: Weld auto gas tank


Magnet???????????
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