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How to Patch a Gas Tank: The Best Methods

Fixing a Gas Tank

This blog post will teach you how to patch a gas tank, so that you or your customer can continue driving your car without fear of leaking or running out of gas. We think replacing a gas tank is the best option but if that isn’t possible, check out three methods for patching a gasoline leak in the underbelly of your tank: with super bond glue, epoxy or a silicone sealant. All three methods follow a similar pattern and will work on most small leaks in most cases; but there are some differences which we will discuss below. Which method is the best? I’ll let you decide as working with glue on a gas tank is a highly dangerous and sticky situation.  Extreme caution is advised!

Fix a gas tank with Super Bond Glue

First, let’s look at our favorite method on how to fix a gas take with super bond glue. Super bond glue is not super glue but is more like an epoxy on steroids!  After jacking your car or vehicle off the ground, quirt some glue over head onto the leak or hole. Remember to always get all of the gas and grease off first. Once the hole is coated with glue, throw some powder filler on the wet area of the gas tank that has the glue on it. Repeat this process ten to twenty times. You may end up using the entire bottle of filler powder in this process.

Gas tanks usually develop leaks due to rust damage. Rust occurs when water gets into the fuel system and combines with oxygen molecules from air over time, resulting in oxidation on metal surfaces inside the tank – this is why it’s important not to leave any liquid behind after draining old gasoline . When rust accumulates on walls of your vehicle’s gas storage unit, the pressure created by gasoline vapors inside will inevitably over time cause a leak.

One of the most common problems is rust on screw threads, which can make it impossible to attach or detach tank parts without creating more damage and leaking gas . If you notice this problem occurring, be sure to clean off all traces of rust before attempting any patching solution. If necessary – if for example your car’s metal parts are already severely damaged from rust exposure – consider replacing your vehicle’s old gas storage unit with one made out of stainless steel instead.

What glue can patch or fix a gas tank

Depending on severity level, some leaks may not even require fitting new metal panels but simply applying an adhesive agent such as silicone sealant in order to stop leakage; other cases might only need glue or an epoxy or a weld.

We’ve discussed how to use Super Bond glue.  But did you know that if you used Super Bond Glue first, you could then coat the rock hard fix with epoxy to strengthen the bond.

Please keep in mind using any type of glue will wear out over time. Welding is always the best option in fixing a gas tank. But if welding is not an option, Super Bond Glue is your second best choice.

Epoxy Adhesive

In most cases, adhesive agents are the easiest and cheapest solution for small pin hole leaks; but don’t expect them to work on larger holes or rust damage (anything more than just superficial) – you’ll need welding supplies in this case . If you don’t have time to order Super Bond Glue, using an Epoxy is another option that’s good at patching metal tanks: it fills gaps between surfaces nicely but might take a while to dry up completely depending on brand used (in some cases epoxies can require 24 hours until they’re completely cured).

Silicone Sealant

Silicone sealant is the most common choice for patching leaks in gasoline tanks. It comes with an ease-of-use advantage, since it can be applied with a simple caulking gun and dries out within several hours to create watertight seals.  But applying Super Bond first will make the fix last five times longer. You can still apply Silicone Sealant on top of Super Bond Glue to get an even stronger bond.


Welding your car’s gas tank means burning through steel panels using an electric current so as to fuse them together into one solid piece; however if the hole isn’t too large, Super Bond glue should be sufficient enough by itself or in conjunction with a secondary topical method of Silicone or Epoxy. We recommend going to www.superbondglue.com to utilize the fastest drying glue on the market. And here are some links to some other products that are also effective:

  1. Versachem 90180 Heavy-Duty Fuel Tank Repair Kit
  2. J-B Weld TankWeld Gas Tank Repair
  3. POR-15 49208 Fuel Tank Sealer
  4. Super Glue Pro Seaz Instant Gas Tank and Radiator Repair

How to patch a gas tank: detailed guide

Patching a gas tank is necessary when the metal of that area has been compromised. There are many different methods to patch it, and they each have their own benefits depending on what you’re trying to accomplish. One of the most common methods for patching a gas tank is with epoxy, and this is typically used when you’re putting in an entirely new floor pan. However, there are some cases where you can use it on just a small area that needs to be patched up.
In order to get started with how to patch a gas tank using epoxy, keep these things in mind:

  • Clean the surface thoroughly before applying glue or epoxy. Use acetone if necessary to remove any oil, grease, rust or dirt from the surface; wipe down with rag after cleaning process.
  • Apply primer (if needed). If metals have been painted over at least once already then apply primer first . Patching only requires one coat of primer if metal is bare.
  • Allow the primer to dry according to manufacturer’s instructions before moving on.
  • Use a putty knife or trowel to apply epoxy onto the surface of the tank, filling in holes and covering damaged areas completely with glue while using masking tape as an outline for your repair area; this will give you a clean edge once dried so that it doesn’t seep out past where you want it.
  • Do not add more than two layers of patching material at one time since each layer needs time (usually about 20 minutes) to cure completely before adding another coat . It can take up to 24 hours for epoxy adhesive used on gas tanks fully set and cured depending upon thickness applied.
  • Allow epoxy glue used for patching gas tanks to dry completely before driving the vehicle.If your car has been leaking gasoline due to rust damage then there are other methods for how to patch a gas tank such as using an epoxy sealer or fiberglass matting with regular polyester resin (gas tank repair kit) which works very well on tanks that have been damaged by rust. Fiberglass repair kits are usually made of layers of fiberglass matting covered with polyester resin which is used to seal up any holes or cracks in the metal, preventing future leaks and allowing you to patch a gas tank without having it replaced.
    • Use petroleum jelly (Vaseline) around the area where you’re applying glue or epoxy so that there will be no issues when working your way from one side to another; this should cover about 12 inches at a time. In addition , wear gloves for protection against chemicals throughout the entire process since gasoline can cause severe skin irritation if exposed directly as well as breathing problems and possible health hazards . Make sure all tools and work surfaces have also been covered with Vaseline so that there won’t be any problems when working your way from one side to another.
    • Make sure the area you’re applying glue or epoxy onto is completely dry before starting how to patch a gas tank process. You can use acetone (rubbing alcohol) if necessary and allow it to air dry for several hours, but make sure all fumes are gone before adding a new coat of adhesive.

    If using fiberglass tape, matting or kit then cut enough pieces to cover damaged area; work in small sections at a time (12″x12″), wet out each strip thoroughly with resin and apply over damage on metal surface being careful not to overlap pieces since overlapping will cause weak areas which may lead to cracks and in some cases may cause the entire tank to explode.

    Work resin into each piece of fiberglass tape or matting being careful not to burn yourself with heat gun since you’ll be using this during drying process, while also keeping an eye on how easy it is for resin to soak up before your work begins getting too tacky (if that happens then wait several minutes until resins stops absorbing). You should end up with a nice flat surface once dried so keep applying pressure, smoothing out any bumps as best as possible while working around gas cap area which tends to stick up more than other parts of metal surface. Allow epoxy glue used for patching gasoline tanks dry completely.

Best Glue for patching a gas tank




This is how to patch a gas tank. In some cases this might be the best way to go about repairing your gas tank. However if there’s screws or bolts that need removed before epoxy can penetrate the metal wall of the fuel container then it will not work because an adhesive needs access in order to bond with both materials involved. In addition always consider what type of filler material you use as well since certain materials don’t respond very well with epoxies and resins especially fiberglass based versions such as auto body fillers designed for vehicle repairs should never be used inside a gas tank.




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