So I am well aware of the issues with leaky rusty fuel tanks in our cars. This weekend I removed the tank in my 90 convert as I wanted to fix the dreaded rivet that runs a hole in the tank and swap out all the hose, seals, etc. I found that my tank is extremely rusty. With chunks of metal coming off the bottom. There are no holes that I can tell but the metal is a bit thin in areas. The tank is no longer available and I am having trouble sourcing a good/decent condition used tank. I have looked at the tank dealer products out there kbs and por-15 which are both a 3 step process to remove rust and put a coating that is compatible with our modern day fuels.

Has anyone used these products or know where to find s good condition used tank?

Thanks!!

 

If you have a decent radiator repair place in your area, and if the sides of the tank are OK, my best recommendation is to ask then to clean off the paint etc on the bottom, and apply a thick coat of radiator solder across the entire bottom of the tank. This is what I did and it is a superb durable repair.
Greg

 

I have seen the solder done but the outside of my tank is in great condition. It is the inside of the tank that is pretty nasty.

 

So I have done a bunch of research on gas tank rust repair. I read one of the large issues with tanks that have been sitting s while with old gas is that they varnish really bad and you get chunks of varnish. So after cleaning the inside of the tank with high pressure water, hot water, scraping, and banging some chain inside, the tank is 90% clean. Next I am going to use the por 15 tank repair kit. I ended up thinking my sump tank was toast due to rust and after the first two steps of port 15 and banging around with some chain. It looks awesome. I literally had to scrap out 1/2" of varnish/hunk from the bottom of the sump tank. Stay toon for more tank repair updates.

 

my fix for rusty tanks!

nice plastic Nascar fuel tank, stainless internals pump, aluminum 1"2 lines, Aeroquip stainless flex lines and fittings, Extruded aluminum fuel rails, 12 new stainless injectors!

only thing on my trunk/boot was Union Jack diecast porcelian.

 

you may realise that if engine has been run with bad contamination of fuel system , possible injectors are partially clogged.

may not show any problems untill max power,fuel flow, runs a couple injectors lean.

may lead to blown gaskets, or scored piston/cylinder.

just a heads up!

 

@ronbros: I complelty agree.

The original motor in the car overheated really bad. The original owner never replace the heater hoses and one burst and apparently kept driving. This was around 2003. It got so hot it melted the distributor cap, there was melted black plastic all in the vee. All the wire harness were extra crispy. So I got the car for super cheap, originally was going to part out the car but it was in too good shape.

So I have put a 6.0 out of a 94 xj12, and have rebuilt fuel injectors and fuel rail. I wanted to clean up the tank and ensure all was good to go prior to firing it up for the first time. the entire fuel system will be compleltly brand new.

Thanks!!

 

I have a 89 xjs convert tank that is in excellent shape if you are interested. I'm in Charleston WV and will send a photo if you like.
Ken in WV

 

A newbie with same issue . Can you please reference the source for tank and other parts that you have used . Thanks in advance

 

been 28yrs since build, but tank and most stuuf came from SUMMIT racing!
things like fuel rails were from a small hotel that remodeled bathroom hand rails , made into perfect fuel rails(gotta think otta the box somtimes).
truth is most of my car very little factory left in it!
ron

 

almost forgot,SAD, car was burned to the ground in a storage fire , trying to forget, lucky for insurance backed by a professional value adjuster, odd did that just last yr?
make sure you carry comprehensive coverage!

 

Thank you ! Love to see detailed pics . Please post when you have a moment.

 

Hi Ken,
Would you still have the fuel tank for the XJS convertible?
Richard