How To Weld a Gas Tank: A Complete Guide to Weld Like a Pro

by James Anderson | Last Updated on February 17, 2023

Since you are here already, you probably have a leaking gas tank.

Aghh! Why can’t these gas tanks do what they are supposed to? I mean their job is pretty simple right. Just to hold few litters of gas every day. Can life get any easier?

Nevertheless, it’s your job to fix it now as like every other time. It’s hard when things get messed up on their own and you got to fix them. Ok enough talk let’s get your problem solved.

I am going to tell you everything on how to weld a gas tank all on your own. Besides, you will get the knowledge to work on similar fixes in the future as these things will let you down again and again.

Why It’s Risky to Weld Gas Tank?

If you have never held a torch in your hand before, I would like to take some time to direct you to the nearest mechanical shop. It’s too risky for a first-timer and things can get ugly.

Welding is all about fire, current and extreme heat. And with fuel tanks involved you are going to deal with flammable liquids and gases. Thus if you aren’t a pro at welding, I would suggest you leave this to a mechanic and spend the day watching Netflix.

Tools Required For A Smooth And Safe Welding

All things said, it not rocket science performing a smooth weld on your gas tank. Few DIY experiences in hand will make sure the proceedings carry out flawlessly without causing any damage.

Below are the additional tools that will ensure buttery smooth welding and all the safety backup in case things go out of hand. This may contain few extras but it’s always good to have tools in stock.

• Welding Helmet
• Safety Glasses
• Oxy-Acetylene Setup
• Welding Gloves
• Angle Grinder
• Chipping Hammer
• Sheet Metal Gauge
• Soapstone
• Metal Brush
• C Clamps
• Portable Band Saw
• MIG Pliers
• Welding Magnets
• Welding Framing Jig
• Speed Square
• Metal File
• Welding Clamps

The Steps To A Perfect Gas Tank Weld

Will things set, lets get you started with your first tank welding. Make sure not to wear an outfit you like because chances are you might have to throw it away after the task is finished.

Disconnect The Battery

The process begins with disconnecting the battery. Place your vehicle in a spot with enough ventilation and turn off every power switch. Then carefully disconnect the battery reducing any chances of sparks and short circuits.

Drain The Fuel Tank

A single drop of fuel inside the tank may prove to be deadly. Thus you have to be extremely careful while draining the fuel tank. Keep the fuel stored in a gas container that has been industry approved to store flammable liquids.

Unbolt The Gas Tank

Now you can bring out the gas tank with utmost precaution. Make sure to avoid any blows or scratches as this may damage the leaks even more. Place the tank in an open space away from the oil container and vehicle.

Wash The Tank

It’s time for your tank to take a bath. Rinse the tank several times with clear and soapy water in turns. This will wash off any flammable liquids left in it. The oils mixed soap water shouldn’t be disposed of in the garden, drains, or street. Store them up in a similar separate container used to store fuel.

Evacuate Fuel Fumes

Any sort of fuel fumes is unacceptable. Thus make the use of an air hose in this regard. Run the air hose for at least an hour. For better results, you can alternate between washing and using the hose multiple times. In this way, you won’t be left with any fumes inside the tank.

It’s Time For The Weld!

Finally, you can proceed to weld. Welding rod, voltage, and joint type vary according to requirements. Thus it’s always recommended to take the advice of a professional on which procedures to follow.

Make sure to put on safety gloves, eye shields and have every safety gadgets in reach. A first aid box always comes in handy doing risky jobs.

Check For Leaks

The weld has to be given some time to reach room temperature. It’s advised to remain patient and let it cool on its own without the application of water. Forceful cooling may result in cracks in the weld.

Now you can fill up the tank with fuel to check for any further leaks. Follow the same procedure in case you find any. And if everything looks good, you can proceed to reattach the tank following the manual.

Frequently Asked Questions (FAQ)

Q. Can you MIG weld a gas tank?

Yes, you can. MIG welding is one of the simplest forms of welding that you can try in your home projects. With little experience in performing watertight welds, you can have all the skills needed to patch up your leaking gas tank.

Q. Will JB Weld hold on a gas tank?

JB weld is well known for its extreme resistance to water, petroleum products, gasoline, and automotive chemicals. The SteelStick epoxy is highly recommended as it can withstand extreme pressure ranging up to 900 psi and hold its form effortlessly even at temperatures as high as 300 degrees.

Q. What is the easiest welding to learn?

Welding is a vast field and may take years to gain expertise. But you can always start with the less complicated sections and move your way up the ladder.

None of the welding processes can be termed as a piece of cake as they require precision skills and improved safety measures. But if you are looking for something to get you started, I would suggest MIG welding which is loved by beginners due to its simple application procedure.

Q. Can I plug a welder into a regular outlet?

Yes, you can. With home projects becoming a new trend, welding is no more confined to industries and workshops. This has encouraged manufactures to produce home-friendly welding machines like the Millermatic 141 MIG.

These efficient machines can run on voltages less than 120V and thus can be integrated seamlessly with your average home setup. But you have to make sure that the other power-hungry appliances like an iron machine, oven and baker are turned off.

Bottom Line

This was everything you need to know to weld a gas tank. A good weld will last you a lifetime so it’s better to get it done perfectly in a single shot. That being said, always put on the protective gear and follow the safety rules because the value of your life surpasses everything.