Split fuel tank ?

[jammypodger]

I have a problem with my 1990 SE - when I fill up with petrol I get some petrol dripping out from under the body - not much but enough to know I have a leak. Also when driving there is a strong smell of fuel.
After a few visits to the garage I find that I can put about 3.5 gallons into the tank without it leaking - so the split is not on the bottom.
I stripped out all the trim from above the tank thinking that the filler pipe might have a loose connection to the tank, but it checked out fine. I now think that the tank may be split at the point it goes through the bodywork i.e. just below where the filler hose is connected to it.

Wanted to know if anyone else has had this problem and if so what did you do ?
If the only solution is a new tank am I likely to find a NOS spare anywhere ?
Also I didn't fancy removing the tank myself as the whole petrol pump removal thing is going to take longer than I have got. So can anyone recommend someone who might take on the job without charging the earth ?

[markv]

Welcome to LEC!

Cracking where the filler pipe meets the tank is a known problem for Elans. Can be repaired - see here (from bottom of the first page) for example. And frustratingly this was the subject of a recall, but for the USA only.

I'm also on the lookout for a replacement tank.

I see you're just down the road - what are you doing on Wednesday night? We have our regular monthly Southern meet not far away at the Hen & Chicken, Upper Froyle, Alton, Hampshire GU34 4JH

So you could come along and discuss all the options on fuel tanks.

See here for full details

[jammypodger]

Thanks for the welcome Markv, and the link about the tank fix.
I know the Hen and Chicken - sister lives in Farnham so I pass it occasionally. I won't be able to make it this Wednesday as wife is out - kids to look after.
I'll make an effort for next month.

[Monty]

I sold a fuel tank from Pinky1 and there was a small crack at the fuel filler neck on the tank, although i don`t think this one was leaking. But here`s a pic which may help u

[Dovey]

Still haven't fitted Pinky 1's fuel tank to my elan yet. However it is sealed now with the aircraft fuel tank sealant and should last a lifetime. Just haven't got around to fitting it yet.

I have the same probs with a strong petrol smell, especially when its over half full. Curiously, there is also a nagging sound coming from the missus about 'the bloody smell' but I do my best to ignore it...

[mickmick]

Wotcha

dont know if this helps, but i have changed my fuel tank, for exactly the same reasons you are getting

mine was split at the 7o'clock position on monty's pic, for about 2 inches in an almost straight down direction

changing the tank is easy if you have the right kit, you will need either a pit, or a car lift as you have to drop the tank down under the car and if i remember right it is about 2 foot(ish) deep

disconecting the pump etc is easy, the really hard bit i found was getting the retaining nuts off the tank straps as mine were very clogged up with crap/rust/road smeg

took me and a mate about 5 hours to do this job, would be able to do it again in about 3 i think, as a lot of our time was spent working out how to do stuff.

another option, simpler than the tank replacement, it to remove the pump/sender unit from the top of the tank, fabricate some sort of patch, remembering to make the hole in it the right size for the fuel "hole", get a bog load of sealant on the face of the patch you will be putting to the tank's interior face and press the patch on.

i did this myself , but made some mistakes and had to do it a couple of times before i got it right, then i sourced a new (second hand) tank and got it fitted

good luck with what you decide to do

Mick

[Dovey]

you will need either a pit, or a car lift

Which is why my new tank is still in the garage, waiting.

[Monty]

you will need either a pit, or a car lift

Which is why my new tank is still in the garage, waiting.

Pinky 1 was on bricks and i removed the tank so it`s possible.

[jammypodger]

Can you give me some more info on the aircraft sealant - i.e. what is the product called, brand name etc., where can you get it, what does it cost etc.
Also, I do have ramps (around about 10 inches high) - does anyone know if I'll get enough clearance to drop the tank out if I decide to take the job on myself ?

[mickmick]

Jammy,

i'm in the army and work on the aviation side of things

one thing we use for aircraft tank sealant is something called PRC

try this link: http://www.silmid.com/prcdesoto/integralsealants.htm

and have a look at it, might help with prices and things

if you do go the sealant route remember its just a temp repair, and you should get the tank changed soon as you can

Also, whe nyou fill it, dont fill it over half way, maybe 3/4s, you'll still get the vapour smell, but at least you wnt get fuel spilling on parts that get hot (rear brakes)

if you have ramps, and axle stands, you could try going for a combination of onto ramps, bricks under jack, jack it up higher, then support with axle stands, bit heath robinson, but if it works it works

You'll also ahve to either drop and swing out, or completely remove the near side lower wishbone too, dont forget to mark the eccentic bolts whe nyou do that so you get the rear wheel alignment right when you put it back together

Mick

[markv]

Page 2 of the very first thread I mentioned ("Monty's Bits") gives a detailed spec on the sealant.

[Ghost]

I don't know if I am having the same problem with a split in the fuel tank!
As I was feeling a bit 'flush' the other day, I filled the tank up fully.
I did a short journey (about 10 miles) and the smell of petrol was very strong. I had the hood up at the time which seemed to increas the smell, as I usually drive with it down, if not in monsoon rain.
The smell decreased when the engine was pulling hard, but increased considerably when the engine was on over-run down a hill!
No sign of petrol on the garage floor and no smell of petrol after the car had been garaged for 24hrs.
I need to sort this problem before Donington, because if I have to travel there with the hood up, I will probably expire or go up in a cloud of flames!
Any serious suggestions will be welcome.

Steve

[mac70]

I had the same problem. First strong fuel smell when I filled up the tank. Then I could see fuel leaking out the tank when I filled it up at the fuel station. It is easy to spot since you can see the tank behind the left rear wheel. The fuel is running down the black tank.
I got it fixed first with a heat and fuel resistent glue. The result was frustrating. Fuel smell again after a few weeks. For me the only solution was a new tank which I just received. It will be installed tomorrow.
My advice; if you do it yourself, repairing the tank might be worth a try. Make sure you use a glue that does not separate from the plastic of the tank. Not all plastic glue are good for all types of plastic. If a garage does it for you, replace the tank. It is 290 Pounds plus vat, which is a lot (especially since I paid additional 70 Pound for shipment to Germany). But letting it exchange several times is more expensive.

Hope, I could help,

Stefan

[Ghost]

Thanks Stefan,
Where did you buy a new fuel tank from?
Is it the original pattern or the modified one for the American Market?
I understand that there was a recall in America due to the problems with the fuel tank spliting at the neck of the filler pipe, and a modified tank was produced!

Initially I was undecided whether the petrol fumes were comming from the engine, from a leaking fuel connection under pressure, or from a split in the tank. I have run the petrol down, and after reaching three quarter full tank the smell started to disapear. It only reappeared after some 'enthusiastic' driving down some twisty lanes which would cause the petrol to 'slosh' about in the tank.

I will have to take the tank out to check it properly, but until then, I will only be part filling up the tank!

Thanks for your comments.

Steve

[mac70]

Hi Steve,

Got it from SJ Sortscars

http://www.sjsportscars.co.uk/partsanda ... mit=search

Cheers,

Stefan

[sheprob]

Have you thought about "plastic welding". I saw an article in Car Mechanics a few months back, where they repaired a plastic bumper.
I'm sure the same could be done for the fuel tank, and I shouldn't imagine it would cost more than £50 top.

Just an idea.

Rob

[Ghost]

I did think of plastic 'welding' as I have seen it done!
The main problem with that is you have to know what type of plastic you are welding to match up the plastic welding material. Also some types of plastic do not respond well to being 'welded' and I don't want to end up with a larger hole to repair!

Steve

[markv]

See also this thread for details of the adhesives/filler used to repair my petrol tank.

[stevieshag]

Mark, i still have a tank.. Pm me if ya interested...

[markv]

Thanks Stevie, but since the repair mentioned in the above link, mine seems fine.