Car ATV Motorcycle Plastic Gas Tank FIX Repair Leak

How to Seal a Plastic Gas Tank

Three Methods:

Plastic gas tanks are in high demand in the world of motorcycle racing and ATV enthusiasts. A plastic gas tank can weigh less than half of a comparable metal gas tank and it is easy to mold into shapes to fit odd configurations. Seamless gas tanks seldom leak and are impervious to the rust and corrosion that affect metal tanks. If a plastic fuel tank does sustain small holes or tears, there are several fairly easy ways to make the repair.


Seal Plastic Gas Tank with Epoxy Glue

  1. Drain the gasoline from the tank and allow it to dry.Sand the area around the hole or crack, and clean the area with a shop cloth saturated with rubbing alcohol.
  2. Mix the 2 part epoxy together and apply all around the perimeter of the opening.Cut a fiberglass patch large enough to cover the opening and overlap it.
  3. Place the fiberglass patch over the hole and press into the epoxy.Apply more epoxy to the patch and surrounding area, pressing firmly to saturate the patch.
  4. Allow to dry, sand the patched area smooth and spray paint with a plastic paint if desired.

Seal Plastic Gas Tank with a Plastic Welder

  1. Buy or rent a plastic welder.Tell the salesperson what you are doing with it to ensure that you get the correct rods.
  2. Remove the plastic gas tank from the vehicle, and set it up in a secure welding area.Drain the gasoline from the tank, and allow it to dry both inside and outside. Don protective eye gear, a welding helmet and welding gloves.
  3. Use a plastic welding rod made specially for this purpose, and fill in the crack or hole.Start at an edge and run the bead completely around the opening. Then begin crossing over the hole, allowing the rod to fill in the hole completely.
  4. Allow the weld to set up, sand it smooth and, if desired, paint it with plastic spray paint.
  5. Replace the repaired plastic fuel tank on the vehicle.

Seal Plastic Gas Tank with a Soldering Gun

  1. Drain the gas tank, and clean it inside and out with soapy water.Lightly sand the perimeter of the area to be repaired.
  2. Cut a plastic patch, made of a similar material to the gas tank, slightly larger than the hole to be repaired.
  3. Heat up an electric soldering gun, and drag it around the edge of the crack to create a trench.Move the gun from side to side to push the plastic back into the trench. While the plastic is still soft from the soldering, lay the plastic patch over the area. Continue moving the soldering gun over the area to smooth the plastic, and fuse them together.
  4. Allow to cool and dry completely.Mix a 2 part epoxy glue, and cover the entire area of the patch. Allow to set up, sand and spray on a coat of plastic paint if desired.

Community Q&A

  • Question
    Can a seam in a lawnmower's plastic fuel tank be repaired using a hot glue gun?
    wikiHow Contributor
    Community Answer
    Probably not. The best way to repair is a plastic welder with a plastic rod that matches the plastic of the tank.
  • Question
    Can I seal a plastic gas tank with fiber glass?
    wikiHow Contributor
    Community Answer
    Yes. Use a product called Tiger Paste, which is fiberglass and resin all in one. The tank MUST be clean of all dirt, grease and oil. Seal the entire tank except for filler and any vent pipes, or pick up tube openings.
  • Question
    Will Flex Shot seal a crack in a plastic gas tank?
    wikiHow Contributor
    Community Answer
    It is doubtful because the gasoline will likely dissolve the adhesive in short time, as well as the rubber portion of that stuff. Epoxy or plastic welding are the best options.
  • Question
    What grit of sandpaper should I use to sand a plastic fuel tank?
    wikiHow Contributor
    Community Answer
    You should use 80 or 100 grit sandpaper. 60 grit will work, as well. The idea is to scuff the area, so that the epoxy will have a stronger bond.
  • Question
    Where can I purchase a plastic welder?
    wikiHow Contributor
    Community Answer
    Plastic welders are quite expensive. Unless you're going to start a tank repair business, it may be smarter to rent one. If you really want to purchase one, there are many to choose from online.
Unanswered Questions
  • Where can I find a company that will fix a plastic gas tank?
  • Will flex shot seal a crack in plastic gas tank?
  • Can I use a plastic gas can as a gad supply?
  • My plastic gas tank weeps from around an embedded metal fixture. Can I seal the tank with a liquid poured into the tank?
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Quick Summary

To seal a plastic gas tank with epoxy glue, start by draining the tank and letting it dry. Then, sand the area around the hole or crack with coarse grit sandpaper, and clean it with a cloth soaked in rubbing alcohol. Next, mix the epoxy glue, apply it over the opening, and press a fiberglass patch over the epoxy. Let the epoxy dry, then smooth out any bumps or unevenness with sandpaper, and spray paint with plastic paint if desired.

Did this summary help you?
  • Using epoxy glue is the easiest way to seal a plastic fuel tank, but it sometimes fails after a short time.
  • If using a plastic welder for the first time, practice before attempting to seal the plastic gas tank. The rental store should be able to work with you to ensure that you have no problems.


  • A plastic welder is safe around gasoline and gasoline fumes, as it has a very high flash point. However, use common sense and do not use near open flames.

Video: Plastic Gas Tank Repair - Fast & Easy Small Engine Fix

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Date: 07.12.2018, 13:23 / Views: 73192