gas tank rebuild story

["Gary H." <spigot2039@xxxxxxxxxxx>]

A while ago we had a long discussion here about repairing gas tanks, which we concluded *can* be done--if done correctly. If not done right....I'm forwarding the below story from the current Rock Auto Newsletter.

Thanks,
Gary H.

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"A friend of mine visited a car wash after we had just upgraded the exhaust system on his 1991 Dodge Spirit R/T. The exhaust caught on the wheel positioning guides for the automated carwash, pushing an exhaust clamp into the gas tank and puncturing it. In a matter of a few miles he went from a full tank to barely making it up his driveway before running out of gas.

"My friend had just purchased a MIG welding setup, so we decided to fix the hole by welding it shut. We removed the gas tank, filled it with water as much as possible using a garden hose, and rinsed it carefully. We couldn't fill it completely with water due to the positioning of the fuel filler neck, but figuring we were safe, we settled down on his front lawn to weld the hole shut.

"As soon as he pulled the trigger on the welding torch there was a sound reminiscent of a fighter jet blasting overhead just over the treetops. I had been standing, but when the noise stopped, I was laying on my back and couldn't recall how I'd gotten there. My friend was also flat on his back, welding torch still in hand, looking stunned. His neighbors came outside and were all looking around wondering where the thunderous noise had come from.

"Apparently the small space in the tank that was not full of water had sufficient fumes in it to ignite causing the explosion. The 16 gallon gas tank had emptied itself completely of water in a fraction of a second, leaving only steam wafting out the filler neck hole. It had also doubled in size, expanding like a balloon, but fortunately hadn't blown to pieces. We avoided any injury beyond the ringing in our ears and wounded pride.

"Needless to say he bought a new gas tank and we never attempted to weld a gas tank again.

"Matt in Washington"


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