Re: I need some parts for my '71 Hornet...

[farna@xxxxxxx]

On November 10, 2005 Michael Hecht wrote:

> Fuel tank (mine has a 1 1/2" hairline crack from SOMEONE ELSE
> backing up without paying attention) or at the least some good
> repair advice on this, jb weld is not quite good enough, it held
> for a year but now it's leaking again and the crack didn't
> spread...)

JB Weld should hold, I've made repairs like this before. The problem is you need something to keep the crack from flexing. 

1. Pull the tank (again?). This time you'll be doing some drilling.

2. drill a "stop hole" at each end of the crack. A 1/8" hole will be fine. It should be as near the end of the crack as possible, but MAKE SURE the hole is at the end! If it is slighty deyond the end but in-line with it that is fine -- the crack will stop when it hits the hole. Just make sure it's only SLIGHTLY beyond the end or the crack could change direction and go AROUND the hole! This "stop hole" is a MUST for cracks in anything -- plastic or metal. Do this before repairs, even if welding. 

3. Since you don't want to weld on the gas tank, get a small steel plate. Not galvanized, but plain steel. Aluminum would be a second choice. Make the plate so the it covers the crack with at least a 1/2" border on all sides. If it's a straight 3" crack, you need a 1"x4" plate. 

4. Drill the plate and tank for pop rivets or small screws, whichever you have access to. One on each corner, one ever 1-1.5". Don't rivet in place just yet!

5. THOROUGHLY clean the tank in the area the plate will cover and the plate itself. Scuff both up a bit with sand paper or a wire brush, then wipe down with mineral spirits, alocohol, or paint thinnner. Gasoline leaves a residue! 

6. Get your screws or rivets and tools ready. Mix some JB Weld and cover the crack or area on the plate that will cover the crack. Also put some JBW around and over the screw/rivet holes. You need about a 1/2" strip of JBW on the crack, no need to cover the entire plate. You have about three minutes to work, should be plenty to mix then put the plate in place. The screws should seal with just the JBW around/over the holes. Rivets will need some JBW over the center hole when done. 

This repair should hold! Anything more than a small hole needs reinforcing when repairing. 

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