Fuel Tank Question

Ohmess

I wanna DRIVE!
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So, last weekend I pulled my fuel level sensor, thinking I would replace the gasket at the top and solve my fuel leak problem which arises when I completely fill my tank. I discovered that the gasket was in good condition, but I encountered something I did not expect.

The sender had a mild, easily removable layer of rust about halfway up, the electrical connections outside were somewhat corroded (as all of the connectors in my car seem to be), and the top of the sender where it seats into the tank had a mild level of corrosion. I cleaned all this up, and cleaned out the filter at the bottom, which was pretty clogged. (My car starts much better now.)

I then noted a some rust around the opening in the top of the tank. After inserting a rag into the tank and cleaning up the opening with steel wool and WD40, I pulled the rag, reached my finger into the top of the tank and felt around the roof of the tank. I felt a thin layer of rust on the top of the inside of the tank. I barely touched it, knowing that I would be knocking rust into the fuel if I did more.

I fear asking this question, but how bad is this? I presume I need to pull my tank and clean it out, but am not sure how to clean the inside of the tank (Naval Jelly??).

Again, I have a million things to do to my car and am trying to triage, but I am concerned about what may be in the tank and that I may have consistent fuel deliver problems until this is cleaned out.
 
Thanks Stevehose; that doesn't look too hard actually.

How do you seal up the tank opening when rolling the tank around to get the entire inside of the tank cleaned and coated? Gorilla tape, maybe?
 
Yes tape is good, I used duct tape / race tape
I also went one step further and had the tank dip striped first before the POR 15
 
Did you pay someone to do the drip strip?

After, did you marine clean, then metal prep, then seal? Or did you just drip strip and seal?
 
Yes, I just taped it up. My exterior was ok, I sanded and repainted.

Thanks Stevehose; that doesn't look too hard actually.

How do you seal up the tank opening when rolling the tank around to get the entire inside of the tank cleaned and coated? Gorilla tape, maybe?
 
Per Steve, the POR-15 system seems to be the standard. Chris, before dipping, which would be great if you have a place near-by to do it, I would do the full Eastwood treatment and let it dry for 3X as long as they say :).

I get no sediment in my filter now so I think it's a good and safe fix. But do be really careful- gas can explode. Don't let any of those smokers near you when you're working on it!

Peter
 
Had it dip stripped, then marine clean, then POR.
Just make sure if you get it stripped that the company doesn't put any coating on it to stop surface rust.
The company that did mine does this but you can ask for it not to be put on.

My tank was in a bad way and needed the panel shop to do quite a bit of rebuilding on it..rust, rust, rust
 
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