Apply an Epoxy Sealer on a Leaking Gas Tank

Reader Contribution by Keith Fellenstein
Published on October 21, 2013
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I have never been a fan of using tank sealers, but sometimes you don’t have a choice. Recently, the tank on my 1964 Triumph T100SC started seeping at a spot weld under the right side strut securing the tank kneepad. I didn’t want to repaint the tank, so the easiest fix was to epoxy coat the tank and seal the leak from the inside. 

Fortunately, this is a project within most people’s grasp. It’s not a difficult task, but careful preparation is key, especially if you have an expensive paint job to protect. Materials needed include bolts or rubber plugs to seal the fuel tap threads, a rubber bung to seal the filler neck, plastic wrap and newspapers to protect the paint, rubber gloves to protect your hands, a container for mixing the epoxy, a mixing stick and the sealer, of course. Finally, a clean workspace with enough room to move the tank around so the coating is evenly applied is important.

When choosing a sealer, make sure it will stand up to the ethanol in modern gas. A Novolac epoxy sealer such as Caswell sealer will do that. Prepare the tank by removing anything you can unscrew from it, such as badges, filler cap, fuel taps and kneepads. If you use bolts to seal the tap holes, wrap them with Teflon tape. If you use rubber plugs, push them in firmly. You don’t want any epoxy leaking out.

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