Rusty ATV gas tank - fix or replace?

[SteveH-CO]

1985 Honda Foretrax 250 gas tank - more than a few pinholes.

Could try to fix with POR-15 gas tank sealer (using a patch for the larger areas) - $18. Could replace with aftermarket new plastic tank for $130. Metal tanks are double that, used, with rust. New tanks are unobtanium.

Is this worth trying to save? This ATV was a freebie my daughter and I are fixing as a learning project for her, so I likely won't keep it long term. But, I still want to repair it correctly.

 

[motodad]

The cheapest way would be to just build up that side with JB Weld. Used to use that in my road racing days for both gas tanks and case covers, its oil and gas resistant.

 

[ZRX61]

With that many holes I'd just weld a patch over the entire area.

 

[theoldwizard1]

Buy the plastic tank.

 

[rkevins]

http://https://www.kbs-coatings.com/tank-sealers.htmlI used a kit from them to repair a diesel tank on a tractor

 

[Griff93]

Marine fuel tank epoxy works well to line tanks like this. Weld a patch and line it if you don't want to buy a new tank. Nothing wrong with buying a new plastic tank either.

 

[Farrier]

With that many holes I'd just weld a patch over the entire area.

You mean cut out and then patch right?

 

[ZRX61]

You mean cut out and then patch right?

If he's confident he could. Could just patch it & lap weld it in place. I assume he's going to clean the inside of the tank of any rust first.

 

[dadsEH]

Ahhhh.......NO.

 

[SteveH-CO]

Thanks for the replies.

I ordered a plastic tank, but as a matter of pride, I may try to weld in a new patch panel in the worst area. It will be a test of my welding skills. One thing that concerns me about using coatings and fabric is that it could fail at the worst time (down the road) and dump gas on your leg or the engine, or dump it in your garage. I also don't relish future rust issues and continuing small rust particles trickling through the carburetor. I'll post pix of my weld job, when I go that route.