How to Remove Rust Inside a Petrol Tank and Prevent Future Corrosion

Dealing with rust in your bike's fuel tank can be a major headache, but with the right approach, you can avoid costly replacements. Here's a detailed guide on how to remove rust and ensure your tank remains rust-free.

Initial Assessment

If you've noticed your fuel tank getting rusty, the first step is to assess the situation. While replacing the entire tank is a drastic measure, sometimes it might be the only solution if the rust is too extensive. However, before you resort to a replacement, consider simpler methods to clean and protect your tank.

Chemical Cleaning and Manual Removal

One effective way to remove rust is by using a combination of transmission oil and a solvent. Transmission oil can help act as a barrier against further corrosion, while a solvent like kerosene or a specialized cleaner can help dissolve existing rust.

Remove the fuel line and drain any remaining fuel from the tank. Pour a generous amount of transmission oil into the tank and let it sit for about six months. Once the oil has settled and the rust has loosened, drain the tank and clean it out with gas or a solvent. Check the tank with a light or a bore camera to ensure it is rust-free. Perform the cleaning process again if necessary until the tank is shining and free of rust.

Physical Removal

For a more thorough clean, you can use physical methods to remove surface rust. This includes manual abrasion using deburring stones or sanding tools.

Fill the tank with a mixture of stones and water. Shake the tank vigorously in all directions to allow the stones to scrape off the rust. Repeat the process with fresh water until the water runs clear. Check for any leaks and perform any necessary repairs. Drain the tank and dry it thoroughly, either using a vacuum cleaner, a hair dryer, or an oven set to low heat (60-80°C). Seal the tank with an epoxy tank sealer if desired to prevent future corrosion.

Preventive Measures

Once your tank is clean, it's essential to take preventive measures to avoid rust in the future. Here are some tips to keep your fuel tank in good condition:

Protective Covering: Keep the inlet of your fuel tank covered to avoid rainwater from entering the tank. This can be done by taping up the hole with duct tape or a similar material until you can perform a more thorough cleaning. Shelter from Elements: Store your bike in a sheltered place to protect it from the sun and rain, as both can contribute to rust formation. Regular Cleaning: Regularly inspect and clean your fuel tank to catch and address any rust early.

Advanced Methods

For persistent rust, more advanced methods may be necessary. These include:

Chemical Cleaning: Use chemicals designed to dissolve rust, but be sure to follow the manufacturer's instructions carefully. Mechanical Sand Tumbling: This process can be done at a professional workshop where the tank is tumbled with fine sand to remove rust. Proper Coating: Apply a gasoline and solvent-proof coating, such as epoxy paint, to prevent future corrosion.

Rust Inhibitor Fluid

If you find yourself dealing with rust in your fuel tank, consider using a rust inhibitor fluid. This fluid can be poured into the tank, sealed, and shaken to distribute the inhibitor evenly. This method helps protect the tank from further rust buildup.

Professional Sandblasting and Epoxy Coating

For the most stubborn cases, professional sandblasting and epoxy coating are recommended. This process thoroughly removes rust and provides a barrier against future corrosion.

By following these steps, you can effectively remove rust from your bike's fuel tank and prevent future corrosion, extending the life of your bike and ensuring safe and reliable operation. Remember, regular maintenance and proactive measures are key to keeping your bike in top condition.