Simple Ways to Get Rust Out of a Gas Tank

A rusty gas tank is a massive cause of concern because it could render your vehicle useless, often leading to an expensive trip to the auto repair shop. Luckily, there are ways to get rid of the rust before it could damage the tank.

How to Get Rust Out of a Gas Tank

You can remove rust from the tank using abrasive materials, chemicals, electrolysis, or chemical resealing treatments.

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Pro Tip: The problem is that gaining access to the entire inside of the gas tank can be very difficult, so special equipment and methods may be necessary. Replacement gas tanks don’t cost that much for most vehicles, so it’s best to just replace the tank whenever possible if it’s loaded with rust.

If a replacement tank isn’t available because of the age or uniqueness of the vehicle, here are some methods for removing rust:

Use Abrasive Materials

Abrasive materials have small mineral particles that can scour off tough dirt, stains, and rust from surfaces. They can also deep clean and polish, depending on their material.

Some abrasives you can use for the gas tank include gravel and loose nuts.

The first step to cleaning your gas tank with abrasives is to remove the part from your vehicle. Then, combine the abrasive material with water, a soap and water solution, or a compatible cleaning solution (one that won’t further damage the tank).

Add the abrasive materials with your choice fluid to the gas tank and swish it around to loosen the rust.

Apply Cleaning Chemicals

Most cleaning agents have chemicals that work well against rust. For example, vinegar and baking create a chemical reaction that loosens rust. Muriatic acid and isopropyl alcohol have the same effect, so you can also use them to clean your gas tank.

You can combine these chemicals with abrasive materials to deep clean your gas tank. Follow the same procedure: mix the solution with abrasives then move them around to dislodge dirt and rust.

Use a Loose Hose and High Water Pressure

If you can securely attach a piece of flexible but tough rubber ¼ inch hose about 3 feet long, feed it down into the tank, and then securely attach a pressure washer nozzle to it, you can clamp the pressure washer pipe to the tank and let it blast into the tank (with the tank inverted so the water will run out constantly).

This will cause the rubber hose to whip around inside the tank like a snake. If you let it do this for a while, it will eventually remove all the loose rust from inside the tank along with any other loose material. This method is used in parts of Europe for fuel tank cleaning.

Perform Electrolysis

Electrolysis or electrolytic cleaning involves using an electric current in an electrolytic bath to get rid of rust on metal and other electric conductive surfaces. It’s a cheap and effective method that leaves metals with little to no damage.

To perform electrolysis, you’ll need a 12V battery, a piece of ferrous metal, a metallic container, and sodium carbonate. Then, follow these steps:

Remove the gas tank and submerge it, as it needs to be submerged in the container. Once the preparations are done, follow the steps below:

• Step 1: Fill the metallic container with sodium carbonate.
• Step 2: Submerge the gas tank and the ferrous metal in the container.
• Step 3: Connect the corroded part to the negative polarity of the car battery while the metal is connected to the positive polarity.
• Step 4: Wait for the battery’s electricity to remove the rust and deposit it on the ferrous metal. It could take an hour to several days to finish, depending on how corroded the tank is.

What Should I Do if I Can’t Get the Rust Out of the Gas Tank?

If the gas tank has holes or damage from the rust, then it’s better to replace it instead of removing the rust.

Driving a vehicle with a damaged fuel tank is a massive safety hazard. It might cause fuel leaks and affect fuel gauge readings, which could keep you from refueling your tank. Worst case scenario? You get stranded on a highway or in the middle of nowhere due to an empty tank.

Here are the usual steps involved in replacing a gas tank:

• Step 1: Drain the old fuel tank by loosening the small stop valve of the fuel tank. If there isn’t any valve, remove one of the fuel lines to drain the fuel.
• Step 2: Remove the fuel lines. One should be attached to the engine and another at the top of the tank. The last line will reduce the pressure of the petrol moving through the tank.
• Step 3: Remove the tank by dropping the suspension (if it has one).
• Step 4: Remove the metal straps by unbolting them. Place the replacement tank in the same spot as the old one, and secure it using the two straps you removed.
• Step 5: Apply the previous steps in reverse to connect the new tank to the other components.
• Step 6: Inspect the tank to ensure for leaks, especially around the pipes and lines.

Signs of a Rusty Gas Tank

If you smell gas inside your ride or spot gas leaks when you inspect your vehicle, your gas tank might have rust. Both signs could mean that severe corrosion has penetrated and created holes in the tank.

Gasoline Smell

The distinct scent could be coming from a leaking tank due to corrosion damage. The gas vapors are extremely hazardous, as they could irritate your lungs. The chemicals could also enter the bloodstream, killing tissues in your body.

Gasoline Leaks

Too much rust can corrode the gas tank, leaving holes for gas to leak through. Not only will the leak slowly drain your fuel, but it can also increase the risk of a fire starting in your ride. After all, fuel is combustible.

Depending on the hole’s size, dealing with it could involve patching the damage or replacing the tank.