Fuel Tank Leak

[Hammerdn]

Pulled fuel tank out today. Had small leak all week,tightened all fittings. Went for a ride and by the time I came back leak was a lot worse. So I drained what gas I had left and pulled the tank. Upon first inspection really did'nt see anything obvious except for a spot where one of the frame tubes had been rubbing on the tank right at the sump. Didn't seem to be any holes worn thru. Filled the tank with water and did an inspection. No leaks where it had been rubbing but it was leaking somewhere. Finally after rotateing the tank around and letting it sit a few minutes in each position finally found it. It was on the bottom front weld seam. When looking at it you can't tell that the weld is not complete, but when you add liquid to it you can see it seep out. It just puzzle's me that it hasn't started leaking sooner. Then I guess it has since I could smell gas from day that I bought it. I guess it was so small that it didn't leave any drops on the ground until now.

Now comes the flushing and airing out proccess before I start tig welding on it.

I guess this will be a good time to add some weld to the brackets and add some foam strips to the brackets and braces and a other place it might rub or come in contact with anything and it should add to the sound deading and vibrations.

Anything else I might want to do while I have the tank out?????

Just wanted fellow Troopers to know where to look in case they have a mystirious fuel leak they can't find.

Hammerdn

[rocmoc]

If you have never welded on a tank there are two lines of thought. Fill the tank with CO2 or soapy water. You can just weld an empty tank. Be really really careful. I have done it a couple of times but always nervous when I did it.

rocmoc n AZ/Mexico

[Hammerdn]

If you have never welded on a tank there are two lines of thought. Fill the tank with CO2 or soapy water. You can just weld an empty tank. Be really really careful. I have done it a couple of times but always nervous when I did it.

rocmoc n AZ/Mexico

Thanks for the advise. I was planinnig on purging the tank with straight Argon but CO2 would be a better option. Have done it before without any problems, but there is always a first.

Hammerdn

[Guest Lenny]

I always run a fan blowing into the the large hole in the tank for a three or four hours. Have the filler cap off and make sure you can feel air comming out of all the other openings. Afterwards, if I can't smell any gas, I know I'm good. Don't let it set around though, gas could seep out of a crevis and create a fuel/air combo in the tank. If it sets, re-fan it. If you haven't added a sump to your tank to prevent you from running out of gas when going down hill, you may want to consider that too. Look at past threads for the various fixes used.

Lenny

[Hammerdn]

I always run a fan blowing into the the large hole in the tank for a three or four hours. Have the filler cap off and make sure you can feel air comming out of all the other openings. Afterwards, if I can't smell any gas, I know I'm good. Don't let it set around though, gas could seep out of a crevis and create a fuel/air combo in the tank. If it sets, re-fan it. If you haven't added a sump to your tank to prevent you from running out of gas when going down hill, you may want to consider that too. Look at past threads for the various fixes used.

Lenny

Was looking at the option of putting in a front sump and also found a fuel cell that would fit into the space where the storage box is under the driver seat for a auxilary tank for more fuel cap.

Hammerdn

[Guest Lenny]

Was looking at the option of putting in a front sump and also found a fuel cell that would fit into the space where the storage box is under the driver seat for a auxilary tank for more fuel cap.

Hammerdn

Running a line out the back of the tank and the front also, if hooked up to the same pump, won't work. It will always draw from the source with the least resistance which is the fitting above the fuel line.

[Hammerdn]

Remember seeing a post on adding a sump to the fuel tank but can't find it. Can't remember if you installed check valves at each end or not . Seems to me it would be the wise thing to do, to keep from sucking in air.

[Guest Lenny]

Remember seeing a post on adding a sump to the fuel tank but can't find it. Can't remember if you installed check valves at each end or not . Seems to me it would be the wise thing to do, to keep from sucking in air.

Go here and read the entire set of post, about 6-7 pages worth. You will get the blow by blow of the gas tank issue with various fixes and lots of pics. Rocmoc and myself have added central tank bottom sumps and Kinarfi added a second sourcing canister.

http://www.utvboard.com/Fuel-Tanks-and-Mods-t629.html

Lenny

[Hammerdn]

was just going thru the posts and pics

thanks again

Hammerdn

[ksimpsy]

I had my tank out and I cut off the stock mounts and welded on a full piece of angle but 3/4" higher so i could put in vibration isolators. I also put an extension on the filler neck so I could fill it with a jerrycan. I have an old tank, i guess the new tanks already have the long filler spout.

Kevin