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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | W460 Fuel Tank Rust Repair I have finally gotten around to fixing the leaks in my fuel tank. After dropping the tank, I discovered that there is considerable rust across the bottom of the tank and around the seam. I have decided to fiberglass the entire tank in order to seal it and protect it from further rust. The first order of business was to thoroughly clean the tank with a wire brush and a lot of degreaser. Then I applied a rust converter to provide a solid base for the fiberglass. Edited by AirheadNut 12/1/2016 9:48 PM (IMG_0357.jpg) (IMG_0357.jpg) (IMG_0361.jpg) (IMG_0362.jpg) Attachments ---------------- IMG_0357.jpg (171KB - 0 downloads) IMG_0357.jpg (171KB - 0 downloads) IMG_0361.jpg (138KB - 0 downloads) IMG_0362.jpg (132KB - 0 downloads) | ||
#234669 | |||
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bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | Re: W460 Fuel Tank Rust Repair How is the inside the tank? You can rust prep that with an epoxy type sealant (www.tankcure.nl). I've used some Fertan (Tapox) products on motorcycle tanks before (http://www.fertan.com/products/tank-reconstruction/tank-sealing-cleaning-kit/). Maybe start looking for a plastic tank and be done for the next 25 years gr. bram | ||
#234672 - in reply to #234669 | |||
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w.james Veteran Date registered: Jun 2006 Location: New Jersey Vehicle(s): 84 280 GE 617A 5sp getrag Posts: 239 | Re: W460 Fuel Tank Rust Repair Did the fiber glass thing 10 years ago. Did not hold up well. I even went so far as sand blasting the tank before the epoxy. I think expansion and contraction of the metal vs. the fiberglass made adhesion a problem. After trying a couple of times, gave up and bought a plastic tank Best of Luck with it W | ||
#234673 - in reply to #234669 | |||
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Boy G Expert Date registered: Feb 2007 Location: Bushveld, South Africa Vehicle(s): Diesel G's: 617A and 602 Posts: 1683 | Re: W460 Fuel Tank Rust Repair There is an epoxy paint by Jotun that will work well there. It is called Jotamastic 90. You will need to overcoat it with an auto enamal though. Alternatively Jotun Hardtop Flexi. Adheres very well to light surface rust and needs no further coatings. | ||
#234676 - in reply to #234669 | |||
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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | RE: W460 Fuel Tank Rust Repair Thanks for the input! I didn't know that plastic tanks were available, but I did some searching and came up with this: http://snowgwagon.blogspot.com/2015/10/fuel-tank-repair-or-replace.htm And this: https://www.partacus.de/ersatzteile/detail/865e54cdc5a716f8a4ca0eed5... The tank is pretty reasonably priced, especially since the sales tax is not applicable to me here in the US, but I think that for the time being I will spend the $30 in materials to fiberglass my existing one and get the G back on the road. If it doesn't end up working well it is good to know that there is an OE option The inside of the tank looks pretty good as far as I can tell, but since the truck came with a POR15 tank seal kit I will use that to make sure. Edited by AirheadNut 12/2/2016 2:05 PM | ||
#234677 - in reply to #234669 | |||
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DUTCH Administrator Doppelgänger Date registered: Apr 2006 Location: US, GA, Atlanta Vehicle(s): 2015 Audi Q7 3.0 TDI,2018 Sprinter Posts: 9963 | Another Option http://www.gas-tank.com/ | ||
#234680 - in reply to #234669 | |||
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bram_r Expert Date registered: Apr 2007 Location: the Netherlands Vehicle(s): 1984 MB 280GE, 1982 MB 300GD, 1986 Subaru XT 4WD Posts: 1659 | RE: W460 Fuel Tank Rust Repair AirheadNut - 12/2/2016 8:02 PM If it doesn't end up working well it is good to know that there is an OE option Please note that when you start looking for a plastic tank, you buy one for your 280GE with fuel pump connection at the bottom. The diesel tanks got different fuel hose connections at the top (and with different diameter). gr. bram | ||
#234687 - in reply to #234677 | |||
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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | RE: W460 Fuel Tank Rust Repair Please note that when you start looking for a plastic tank, you buy one for your 280GE with fuel pump connection at the bottom. The diesel tanks got different fuel hose connections at the top (and with different diameter). gr. bram Good to know, I hadn't thought of that! | ||
#234701 - in reply to #234687 | |||
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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | RE: W460 Fuel Tank Rust Repair I figured I should follow up on the route I ended up taking with my fuel tank. Rather than using fiberglass, which could crack and create ideal conditions for crevice corrosion, I decided to use a zinc based paint to prevent further corrosion, and protect it from being chipped by covering it with rubberized undercoating. On all of the o-ring mating surfaces and hose bungs I covered the zinc paint with regular spray paint to create a good seal surface. These places were masked from the undercoating. On the inside I used a POR15 fuel tank seal kit to seal up the little leaks and take care of any rust that might be present there. The larger leaks were sealed from the outside with JB Weld before the POR15 product was used. I also replaced the heat insulation where the exhaust goes. I am working on building a new skidpan for the tank, as the old one was pretty badly rusted. It will be made out of 18ga stainless.
Edited by AirheadNut 1/17/2017 5:05 PM (IMG_0375.jpg) (IMG_0376.jpg) (IMG_0380.jpg) (IMG_0381.jpg) Attachments ---------------- IMG_0375.jpg (89KB - 0 downloads) IMG_0376.jpg (101KB - 0 downloads) IMG_0380.jpg (102KB - 0 downloads) IMG_0381.jpg (98KB - 0 downloads) | ||
#235102 - in reply to #234669 | |||
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Otiswesty Administrator Date registered: Jun 2007 Location: Portland, Oregon Vehicle(s): 463.241, 461.213 Posts: 3004 | Re: W460 Fuel Tank Rust Repair Nice to see the double saddle tank connections. Brings me back. Slava81 on ebay has sold a few G500 tanks for well below retail as well. He is a Portland area premium auto dismantler. | ||
#235103 - in reply to #234669 | |||
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Atl-Wagen Member Date registered: Sep 2014 Location: Atlanta, Georgia Vehicle(s): 80's something w460-230ge 2013 Honda Ridgeline Posts: 47 | Re: W460 Fuel Tank Rust Repair That looks great! I really like the POR-15 product line, but it sure isn't easy on the wallet. What type of heat shielding did you end up using? | ||
#235124 - in reply to #235102 | |||
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oskar Elite Veteran Date registered: Sep 2006 Location: Lyons, CO Vehicle(s): 1981 280GE, 2002 G500, 280SE 4.5, Audi A4 1.8T Posts: 708 | Re: W460 Fuel Tank Rust Repair Atl-Wagen - 1/19/2017 8:27 AM That looks great! I really like the POR-15 product line, but it sure isn't easy on the wallet. What type of heat shielding did you end up using? ?? .... the tank sealer is not that expensive, IMHO : http://www.por15.com/POR-15-Fuel-Tank-Repair-Kit_p_62.html ( Have to do my tank as well, including the saddle tanks ) Oskar | ||
#235128 - in reply to #235124 | |||
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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | Re: W460 Fuel Tank Rust Repair The heat shielding is just a regular automotive foil-backed insulation. I had some left over from another project. I put it on with a spray adhesive. | ||
#235133 - in reply to #235124 | |||
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AirheadNut Member Date registered: Nov 2016 Location: Montana Vehicle(s): 1988 280GE SWB Posts: 31 | Re: W460 Fuel Tank Rust Repair oskar - 1/19/2017 9:47 AM Atl-Wagen - 1/19/2017 8:27 AM That looks great! I really like the POR-15 product line, but it sure isn't easy on the wallet. What type of heat shielding did you end up using? ?? .... the tank sealer is not that expensive, IMHO : http://www.por15.com/POR-15-Fuel-Tank-Repair-Kit_p_62.html ( Have to do my tank as well, including the saddle tanks ) OskarIf you have more than one tank to do, just buy one kit and some extra metal prep and degreaser. If you get both tanks prepped, then you can use the same can of sealant: just pour it directly from one tank to the next. Resealing my tank only used about 15% of the can of sealant. | ||
#235134 - in reply to #235128 | |||
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oskar Elite Veteran Date registered: Sep 2006 Location: Lyons, CO Vehicle(s): 1981 280GE, 2002 G500, 280SE 4.5, Audi A4 1.8T Posts: 708 | Re: W460 Fuel Tank Rust Repair AirheadNut - 1/19/2017 11:41 AM oskar - 1/19/2017 9:47 AM Atl-Wagen - 1/19/2017 8:27 AM That looks great! I really like the POR-15 product line, but it sure isn't easy on the wallet. What type of heat shielding did you end up using? ?? .... the tank sealer is not that expensive, IMHO : http://www.por15.com/POR-15-Fuel-Tank-Repair-Kit_p_62.html ( Have to do my tank as well, including the saddle tanks ) OskarIf you have more than one tank to do, just buy one kit and some extra metal prep and degreaser. If you get both tanks prepped, then you can use the same can of sealant: just pour it directly from one tank to the next. Resealing my tank only used about 15% of the can of sealant. exactly my plan, do all 3 tanks ... Oskar | ||
#235141 - in reply to #235134 | |||
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