Hole in gas tank- can it be repaired?

[ejp2fast]

Welding is the best way to patch the hole. With the tank empty, put about a pound of dry ice into the tank and give a few minutes to "melt" before welding. The carbon dioxide will prevent ignition of an fumes.

Interesting approach, I haven't heard of that before.

[ejp2fast]

just to follow up in closure how this ended up and my experience..
i cleaned and polished the surface really good and tried JB weld - ends up my hole was too big for the JB weld to hold and fully seal the hole- my hole was 1/2 inch long by 1/8 inch wide...
so replacement of the tank was the way to go.

Here is a step by step procedure for replacement:
Tools needed: 10mm, 12mm 14mm sockets and 4" entention if possible
philips screw driver, pliers for jiggling the fuel hoses loose.
Jacks
PB Blaster (maybe)

Prior to removal, drain tank if it isn't already empty for ease of removal... this tank is only 10 gal tank, so even 5 gallons isn't super heavy, but will make it easier.
1. remove rear seat
2. remove drivers side rear panel so you can access the fuel filler hose and connections
3. Take the plugs out that hold the carpet to the body, and peel the carpet back toward the front of the vehicle for fuel pump access and disconnect connector and 2 hoses.
4. Take the filler hose access panel off and unhook all the hoses making note which hoses go where. do not remove any hoses, just disconnect at the gas tank
5. Jack up rear end and secure, then shoot the 4 12mm bolts w/ PB blaster for ease of removal on the 4 corners of the tank..
6. Remove the 10mm bolt that holds the e-brake bracket to the tank, then disconnect the fuel hose on the drivers side lower side of the fuel tank.
7. Loosen the 4 bolts, then remove
8. Tank will need to be wiggled out.... note where the tank flanges hit the axle beam and other places.... I ended up lying on my back on the ground and kind of moving it downward...
9. Tank will come down, then drop the drivers side end of the tank and continue to lower at an angle (to clear the e-brake hose) and tank will move outward and down at an angle and will come out. No need to mess with the e-brake cable, just that bracket in step 6.
Tank is out!
Installation reverse

[Pu241]

ejp2fast
Did you save the tank?
With it out of the car would be much easier to fix for a back up or sell.

[Safety Guy]

Unless the tank's really really nasty, I'd get it cleaned out, dried and permanently welded fixed for who knows what event in the future. Or sell it if you don't have room or desire to keep it.

Karl

[ejp2fast]

I plan on keeping it, yes... would be much easier for weld repair now...

[eurotiva]

try seal-all. It's available at wal-mart or advance. Works awesome.

[Festival]

tank welding

The dry ice method is also new for me. I have seen a gastank beeing brazed after putting the exhaust pipe of a running car for about one hour.

I did,t explode

[WmWatt]

Note epoxy curing varies with ambient temperature.
It needs 70 deg F to fully cure. When building boats
in cold weather I shone a light on it or used a heater.