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Filling pin holes in metal gas tank

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Filling pin holes in metal gas tank

Old 06-15-2015, 09:17 PM
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Default Filling pin holes in metal gas tank

I am working on repairing a Honda EM5000 generator tank that was pretty heavy rusted and leaking fuel. I searched youtube and decided to remove in rust from inside the tank using the electrolysis method. I was able to just about get all of the loose and flaking rust from the inside which is about a measuring cup full. I will still need to use a metal etcher before i apply a POR 15 fuel tank coating. How should i go about repairing the pin holes? Bondo?

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Old 06-15-2015, 09:24 PM
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They make special tank coatings also a good radiator shop could probably fix that tank I have had a few tanks fixed had a steel one that was rusting from the inside out would plug up In a older diesel bus.They cut the tank apart coated the inside welded it back together it didn't have rust holes but I'm sure yours could be fixed.

I wouldn't use bondo the fuel will eat it find a radiator shop that fixes gas tanks don't see why they couldn't fix it.
Old 06-15-2015, 11:50 PM
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If you're having fun, fine. Otherwise just buy a new tank...I'd probably just stick some JB Weld in the holes from the outside (for fun before I bought a new tank).
Old 06-16-2015, 06:55 AM
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Is that a 3.5 gallon tank?
Old 06-16-2015, 07:14 AM
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For $34 you can buy a new one.

Amazon Amazon
Old 06-16-2015, 07:16 AM
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Stop fooling with it, it's a gas tank. Replacements are readily available and easy to install. Why risk burning something down?
Old 06-16-2015, 07:21 AM
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I've mig welded vintage motorcycle tanks. All depends on the surrounding sheetmetal though. You could braze them too.

But if the machine is in good condition, I would fit a generic tank to the frame. Looks like a replacement tank is discontinued, but I found this searching with just the part number: https://shop.weingartz.com/AdvancedW...250&WEBID=7116
Old 06-16-2015, 07:57 AM
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I would replace it.
Old 06-16-2015, 08:07 AM
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Replace it; too much time and labor.
Old 06-16-2015, 08:08 AM
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The tank is shot and I would not trust any repair job. If it held water then maybe but not gas.
Old 06-16-2015, 10:01 AM
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Originally Posted by suzuki140 View Post
They make special tank coatings also a good radiator shop could probably fix that tank I have had a few tanks fixed had a steel one that was rusting from the inside out would plug up In a older diesel bus.They cut the tank apart coated the inside welded it back together it didn't have rust holes but I'm sure yours could be fixed.

I wouldn't use bondo the fuel will eat it find a radiator shop that fixes gas tanks don't see why they couldn't fix it.
I question that, only because I once patched a leak in a truck's fuel tank with Bondo, then ran the vehicle for another 3 years. It didn't leak fuel and the engine ran just fine.
Old 06-16-2015, 03:40 PM
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Replace tank with any good tank if not a replacement.
You can patch it up, test it for leaks with water.
And gas will still leak out cause it is thinner than water.
Old 06-16-2015, 05:09 PM
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Way too much effort - I'd buy a new one.
Old 06-16-2015, 05:48 PM
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Rig the line with bayonet fittings and hook it up to a boat tank.
Old 06-16-2015, 05:50 PM
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Target practice for my Kimber

Last edited by Alureing; 06-17-2015 at 05:13 AM.
Old 06-16-2015, 05:53 PM
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that $35.00 tank should cost you about $300.00 to fix.
Old 06-16-2015, 05:55 PM
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I would price it to see what they would charge to fix it never know my radiator shop has fixed several tanks for me granted they were big tanks which would cost a lot to replace.

You could buy a aluminum fuel tank from northern tool even has a fuel gauge if you want I have used there tank for a generator I did repair on that's another option.
Old 06-16-2015, 05:58 PM
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Originally Posted by fireisland1 View Post
that $35.00 tank should cost you about $300.00 to fix.
It's not $300 to fix I had a 80 gallon steel diesel tank out of a mini bus fixed for $150 bucks it was a big tank size of a table they cut the tank in half cleaned and treated rust then put a coating inside welded it back together.
Old 06-16-2015, 06:02 PM
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Originally Posted by Boat_rook View Post
I am working on repairing a Honda EM5000 generator tank that was pretty heavy rusted and leaking fuel...
Beyond very foolish indeed.
Old 06-16-2015, 06:20 PM
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Here you go never rust again problem with those steel tanks is they are not coated and when not left full of fuel moisture gets in and will rust the tank.

http://www.northerntool.com/shop/too...3776_200413776

Might have to fab up a mounting bracket or get a buddy that has a welder to help these tanks are nice have used them before.

Here is another option marine fuel tank go to the marine store pick up some quick connect couplers so you can remove tank when not using generator or need to refuel tank.

http://www.northerntool.com/shop/too...nks+4294914060

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