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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
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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 |
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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 |
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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. |
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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
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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/ |
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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 |
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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! |
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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.
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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. |
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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? |
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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 |
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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. |
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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 ) Oskar If 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. |
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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 ) Oskar If 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 |
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