Plastic Fuel Tank Repair with a Soldering Iron

I used a standard solder iron to fix the plastic gas tank in my 2016 Toyota Tacoma.
CORRECTION - AT 3:05, I meant half a GALLON, not half a tank.
UPDATE, AUG 28, 2020 - Gas tank is still holding strong! No leaking or weeping.

[@DarrinTorrey1]

Update: Almost 2 and half years later and the repair is still holding up!

[@alex4695]

That’s amazing!! Thank you so much ! The dealer bill for my is350 is 2600$ I’m definitely gonna try this

[@adamwatts8343]

@@alex4695 how did it work

[@duanefelux6969]

Wow! I’ve had a tiny hole in my plastic gas tank since bought my truck from a friend. Been only filling it up a quarter tank since. Tried the putty, didn’t work. Thought of the same way right before I saw this. So excited to give this a shot! Finally!!! Maybe I can get a full tank of gas!!!

[@marcoantoniogalindoherrera2296]

I like that idea tomorrow under the tank of my vehicle to repair

[@johnsandoval4938]

For those people who are worried that the heat from the soldering iron will ignite the fuel, here are the numbers. HDPE (the plastic that fuel tanks are made from) have a melting point of 275F. Gas has an instant combustion temperature of 525F. That's the temperature that the liquid or the fumes will spontaneously combust with just heat, not flame. A soldering iron, depending on the brand, can get as hot as 392-896F. You have to know your tools. Keeping your iron on its lowest setting, staying in a well ventilated area, and having no way to create a spark or open flame, you can do this repair safely.

[@DarrinTorrey1]

3 year update - still holding! To address some of the concerns about safety - it may not have been clear in the video, but the tank was virtually empty, and it was parked on a relatively steep slipe with the rear going downhill. The puncture was at the front of the tank, so there was zero gasoline anywhere near where I was working.

[@EmilyTienne]

But fumes ignite easily. That soldering iron is over 500 degrees F. Gasoline fumes ignite at near that temperature.

[@sunset7389]

Thanks for update the status!

[@DarrinTorrey1]

1 year update... still holding. No leaks or gas smell.

[@williammurray1620]

Is that tank made of Polypropylene? Thank you!

[@Luis-xn6ds]

Thank u

[@MDTAR15]

the update is appreciated...most youtubers dont follow up. Thanks.

[@Exertiions]

I ran over a huge screw believe it or not, all gas is out and the gas fumes are out since I opened the cap, would I be able to use this same method on the car like you did?

[@bobbybrown4652]

Legend :)

[@JJ-gd7gf]

Fuel Funnels are typically made of the same materials as fuel tanks. I trimmed a sliver from the edge of a red funnel to repair a puncture leak on a six gallon gas can I found along the road. It worked like a charm and I filled the tank with water for 24 hours to make sure it didn't leak.

[@DarrinTorrey1]

Brilliant! I will keep that in mind in the future.

[@michaelroberts3844]

From everything i been seeing and reading i think the soldering iron trick is the best

[@jeffbragg7002]

Just used your method ( regular soldering iron an a cleaned up scrap of black oil bottle) to fix a seeping seam on the plastic tank on my BMW K1200LT motorcycle. I'm sure the dealership would have charged around $3k to install a new tank! Thank you for posting this!

[@johndixon40]

I punched a hole 40mm x 10 mm in the fuel tank on my tractor, I have just put the fuel tank back into my tractor after doing your repair it did a great job thanks

[@CHPangler]

Awesome video. So I found a puddle of gas under my truck and found that someone drilled straight into my tank and stole the gas. Shop quoted me 2500 for a new tank, pump, filter, and hoses. Glad you made this helpful video.

[@alocamaro]

Same here man someone drilled a hole on my silverado tank

[@CHPangler]

Mine is a Silverado too!!

[@CHPangler]

Just replaced mine today. Used 2 pieces from old oil jug, one smaller then the other. Got a soldering iron with a flat attachment from Amazon and it worked great. Lifted the truck on one side so the fuel wouldn’t be near the hole, then I went at it. Came out SOLID and I saved $2500. Thanks again!

[@bartbeshootin]

Shit same thing happened to me lastnight to my 1500! this is my next step, because yes tanks are expensive.

[@darriusholt]

Someone just drilled a hole in my tank as well. I have a ram 1500. Are these tanks completely plastic, or is there some metal in them?

[@gman5342]

I did the same thing, what i did diffrent,was melt the plastic to almost liquid in a metal lid/cap and then used a flat tip screw driver and pack the slit with the melted plastic, great video

[@TheReal1953]

Key is to match plastics. That writing under the tank is the code that tells you what plastic was used to mold the tank.

[@abrahamntonya222]

JB weld doesn't work. I tried it myself last night and woke up to my tank dripping this morning. I originally wanted to try your idea but was afraid of combustion. Now I'm more confident I was on the right track after watching your video. Thank you!

[@heavystarch100]

What also works is using old plastic zip ties to melt into the seam. The black industrial ones work best. They often made from Delrin plastic.

[@alexd4102]

Thank you sir. I live in a bad neighborhood my dad's PE gas tank was drilled through. They maybe got away with 1 gallon but ran out of space so the rest of the 14 gallons drained onto the street. Tried tank weld, will do this if it doesn't hold.

[@DarrinTorrey1]

Update: One year and 10 months and it's still holding up!

[@grantmartin4663]

I used your method but with a black comb on a Jeep Wrangler plastic fuel tank and it worked great. I soldier it from inside and out because I have the tank out of the vehicle. Thank you.

[@HiDefMediaInc]

Thanks so much! I did my first repair on a 2016 Nissan maxima attempting to use fuel tank grade JB Weld and flex seal tape. Horrible results but then I saw your video and you saved the day. God bless

[@gibby_gets_it]

Never worked for me

[@HiDefMediaInc]

@@gibby_gets_it Run the gas out, jack it up on the opposite side so that the gas is draining away from it. It’s the Gasolina will not allow it to cure… Hit it with some brake cleaner first

[@gibby_gets_it]

@@HiDefMediaInc how long does it take to cure usually

[@gibby_gets_it]

Cause she ain’t leaking now😂 put a thicker plastic on there and it’s doing decent

[@HiDefMediaInc]

@@gibby_gets_it it will set in about an hour but for a good cure leave it for 24 hours

[@cma8165]

Glad to hear from you that 2 months ago there was still no sign of any fuel leaks. At the 12:00 minute mark you ask if we have any suggestions: Although it is more work, I would have removed the fuel tank and would have done the repair with the fuel tank away from the vehicle. Needless to say, it is safer for the repairman with the fuel tank removed, you have more room to safely work on the fuel tank and you can still test it safely while removed. But again, that's just how I would have worked it. And from time to time, please put out an update to let us viewers know if no more fuel leaks, as we all wanna know. And thanks for sharing your video with others who like you, want to save $$$ on expensive repairs.

[@wedgepower383]

The problem with removing the tank is that you take all the load off the tank to make the repair and then bolt it back in and put stress on it. The best way to repair is to have it in it's natural position. Once the gas is drained it's no more dangerous installed than uninstalled. And really, gas is pretty stable with that type of heat source. Open flame or spark is where things can go wrong.

[@DarrinTorrey1]

Update... 5+ months later and it's still holding strong. No weeping, no fuel smell. 🙂

[@DJizz82]

Great 👍🏽!!!! I have a similar problem with my Nissan

[@ricapache1]

Thank you for the video I’m going to try to fix mine.

[@akhir_s1484]

No for much long lol😂 Ive done this like about 8 times now on my 240sx plastic fuel tank, theres really no possible fix

[@truthseaker3742]

Anyone else thought this was going to end badly for him , I would recommend removing the tank and emptying of fuel , drying and maybe even filling with water before soldering fuel tanks . Fumes are combustible , even more so than liquid fuel. He's lucky to be alive and so is anyone else that has used this ' method '. You have been warned.

[@nosoupforyou425]

@@truthseaker3742 you have been warned? He just schooled you in a video. If your schooling was accurate he would have not been able to post - so you are wrong

[@lilfellergrmc]

Gonna fix my girlfriends tomorrow with the same trick. Thanks for the info. Glad it’s still holding up after a couple years!

[@eduardoyepez7358]

Use to use zip tie for plastic welding. Helps with a ton of crap. Sanding and re welding plus spraying a new coat of paint helps a lot in the end for a good result

[@karlo29]

hi how are you? thank you for your video, im glad it worked out well for you. only thing i can think of different would be to melt in some whiskers of a wire brush or thin wire to act like rebar in the weld. on dirt bike fenders ive added in wire bug screen or even square mesh (small as possible holes) chicken wire and just heated it to melt in and then cover with plastic to bury it. also maybe a wider flat tip for the iron. thats just my 2 cents =-) thank you again. its always awesome to find folks that find a way for us to save a little money on things we are charged ridicules amounts for at shops and dealerships.

[@DarrinTorrey1]

I like your suggestion about reinforcing the repair with wire of some sort. I'll keep that in mind if I have to do this again! Also, I definitely would have used a larger tip if I had one available.

[@RollinMyOwn]

Been fixing pl a sticky thiswaytor at least the last 15 years.... done good enough it's just as good as factory.

[@michaelcastleberry1420]

I did this in my 4 wheeler tank and it worked great 👍

[@DarrinTorrey1]

Nice 👍

[@Hawk013]

So a couple tips, number one is match the type of plastic you're filling the gap with to the tank material. The tank should have a molding stamp on it telling you what it's made of. Second tip is cut your filler material into skinny strip, like welding filler rod. Weldors use rod as filler for a reason, it's really convenient. Just lay the strip in the crack and stir it in.

[@wedgepower383]

I am about to do this on a 78 Dodge gas tank. Hadn't thought about oil bottle plastic. Great solution!!

[@xHamfistedx]

Good job overall. My only recommendation would be to use the flat triangle iron head on your soldering iron. This seems to work much better than the standard round head for feathering in the additional plastic filler material. Other than that I like your repair.

[@jacobnolan41]

It's easier to use a Plastic Welder from Harbor Freight. 16 dollars.

[@bindiberry6280]

I suggest that cutting out a piece of tin pan, wrapping it around the heating element, and then flatten the tip width so to press melting plastic better with heat.

[@DarrinTorrey1]

Correction at 3:05 - I meant half a gallon, not half a tank.

[@lyleherring4499]

I use to do this with a hot butter knife over the stove top and plastic spoons for my model cars .

[@tonytee981]

You have a plastic tank and the JB weld you are holding is for metal tanks. That's why it didn't work.

[@chepe7810]

I have an 06 toyota tacoma. I ran over a metal wired and it slashed my fuel tank. I've tried to block the leakage with jb weld fuel epoxy and it has been holding up but u can see that there's a tiny leakage. Imma try ur method. Thnaks for the video

[@zulfiibrahim]

Great Info Thanx. From UAE

[@DarrinTorrey1]

Glad it was helpful!

[@yhird]

Great work. Great video. Thank you.

[@DarrinTorrey1]

Glad you enjoyed it!

[@eddiearrington8086]

Thank you! Nice work

[@johnwurfel2862]

I noticed the original repair looked like metal tank repair kit. They make a QUIK WELD plastic fuel repair kit, looks like white modeling clay. Might have worked better and also serves as malleable filler after the solder bond.

[@infinitewisdom4557]

Hi. Are you referring to "jb weld, kwikweld, metal, wood, plastic, tile, pvc, ceramic, fiberglass, concrete and more" ... tx

[@ravenfeather7087]

Where there's smoke there's fire. BOOOMMM!!! But you did it. Something I wouldn't do. It's not the liquid fuel that would initially ignite it's the vapor.

[@babaganoosh1969]

Only thing I would have done differently is to shave off or scrape off some of the same tank for filler...great job

[@sky173]

3 years, still holding?

[@DarrinTorrey1]

Yes, still holding!

[@eliseobalderas2145]

Gotta try it man. Thank you!

[@robertsherrick4081]

Very good! Try a bigger iron.

[@mlutfe]

Hi Is there any danger of fire using a soldering?

[@BryanCunningham-n4v]

Could a person use a zip tie as sort of a welding rod or filler material if needed? I'm fixin' to try this on a riding mower gas tank. I have about a 10" separation of the tank at the seam.

[@eslater5219]

Thanks for this mate, going to try it on my Jag 👍🏻

[@echangwang1821]

Really interesting idea. I don't know why a car manufacturer would use a plastic gas tank. That just seems like a recipe for disaster.

[@xTheGamerHeart]

3 main reasons. 1- plastic is highly resistant to corrosion. 2- plastic will melt in fire and start burning the fuel inside it unlike metal tank which will start pressurizing until the tank explode. 3- light weight.

[@Jack-jl2vf]

Easier to steal your gas 😂 crawl under punch a hole and leave you stranded.😂

[@nosoupforyou425]

@@xTheGamerHeart don't forgets it is cheaper for manufacturers

[@jjlmct]

Lighter than steel, cheaper than aluminum.

[@marcoantoniogalindoherrera2296]

tomorrow I repair the tank of my vehicle I will use that option of the soldering iron

[@DGSantaFe]

Mines is leaking gas as we speak, I'm assuming I'd have to drain the tank before I attempt any soldering right?

[@DarrinTorrey1]

Yes, drain or drive it until empty. Try to park on a hill so any remaining fuel sits away from the area being repaired.

[@jacobnolan41]

I used a patch kit that included a resin that temporary stops leaks. Then I used the Plastic welder to fuse the plastic back together. No need to drain the gas.

[@jaycastro1024]

@@jacobnolan41 no need to drain the gas? Is that right cause i would think a electric device next to gas fumes would combust

[@jaimecorona4594]

So the fuel pump is non electrical😂?

[@samuelbrown7108]

You took a crazy risk using heat by the gas tank like that!!

[@granadass]

I know I thought the same thing I thought it would have been better just to drop the tank and drain it and let it air out for a day or two before I did that

[@josem4568]

man crazy I agree smart but dumb at the same time

[@thomaslindell5448]

A better strongsr repair would use sone steal windowscreen and embed it in the plastic

[@kllisk]

I like using metal window screen and inbed that across the crack

[@clintjayphotography4734]

How bad is it if the plastic around my gas tank is cracked? No gas smell or leak in the metal tank.

[@johndbender5250]

Gas in the tank, hot soldering iron...what could go wrong here?

[@ferret13sj]

My thoughts exactly...plus laying underneath so melted plastic can drip on you. Lol. But all ended well.

[@sammaglitto8922]

Boom

[@txjackazz]

Hey how's that tank holding up?.. I have a donor tank for my car but g found that was cracked too. Am thinking of going this route..

[@DarrinTorrey1]

So far so good!

[@DarrinTorrey1]

3 years and still holding!

[@txjackazz]

@@DarrinTorrey1 mine didn't take I tried again trying to melt the plastic more but have have time to do the tanks again.

[@robertbailey8570]

i have a hole in the neck part of my boat tank ..it's the built in tank .. did you drain the gas first ?? ??? thnks for the video

[@DarrinTorrey1]

I did not drain it. I drove it until it was almost empty, then parked it on my sloped driveway with the rear end downhill to get any remaining fuel at the back of the tank. Good luck with your boat!

[@infinitewisdom4557]

Tx for vid... if these pos car makers put an underguard to protect the tank we would not have to resort to such ingenuity...

[@jonlittle3745]

Nice!!

[@fpsnashamdan7362]

If someone knows : can I use the old steel gas tank was installed in 1987 Chevy for the 1992 Buick roadmaster ???. The original roadmaster plastic or polypropylene gas tank is very bad

[@northpole9311]

It's the way to go.... your not introducing a foreign chemical it all stays the same, mixed in = Walla ...

[@blainemonson3414]

Can I cut 6 inches out of the tank and solder it back together? Need to fit an 01 tank into a 69 truck

[@YNB_Fatty]

Did you have to drain the fuel tank before doing this? I'm nervous about having a soldering iron next to fuel vapors

[@DarrinTorrey1]

Nope, I just ran it until there was about half a gallon of fuel and parked it facing uphill on my driveway.

[@oldguy8177able]

yeah i would,i'm doing repair on my fuel tank definately going to empty fuel tank,fuel is a comdustible material crinky you end up blowing yourself and the vehicle to simerines

[@jasaircraft]

Tried both things on my r32gtr leaking plastic tank and nothing, maybe the plastic i used just didnt match the tank's plastic

[@happytobsaved]

I'm trying JB Weld tomorrow

[@DarrinTorrey1]

I tried that at first. IIRC, it lasted a week before it started leaking and peeling off.

[@mervintresreyes9650]

My car got stolen and brought me here coz mf drilled on my tank to get the gas. (One of the problems)...so i think i got a metal tank so i guess its better if i weld that hole using lead? Is that safe? Thanks.

[@rickykey1175]

Son I am not brave enough to do that 04 trailblazer just found a gas tank junk yard they are hard to find because of bad neck on the tank itself

[@Hellbent7069]

Them toyota fuel tanks cost $1000 for one if you can even find one. I think it's best to replace the tank myself.

[@WavyBabySimTV]

How long did it last ?

[@DarrinTorrey1]

Don't know... it hasn't failed..😉

[@DarrinTorrey1]

3 years and still holding!

[@RTD1947]

Gutsy move “ Mav”!!! But thanks!!!

[@armandopatane5343]

Seems to work-/ will try

[@alex4695]

Any updates ? How’s it holding up ?

[@DarrinTorrey1]

Still holding!

[@alex4695]

@@DarrinTorrey1 good stuff ! I’m gonna try it just scared if combustion

[@ironicmanx9886]

Any tips for fixing an inch size hole from someone stealing my gas. I tried leak fix didn't work properly because it needs to be completely dry

[@tammyyerian7631]

same method! Use plastic from zip tie or oil bottle and slowly melt it together like he did in this video.

[@truthseaker3742]

Drill out and install a bung from a water container.

[@jjlmct]

I can’t believe you didn’t Blow your Face Off! You Lucky, buy a Lottery Ticket.😮😮😮

[@stevemitchell238]

YOUR NUTS heat and fule not a good combo if gas comes out and drains in to that handel where the switch is or in the windings your next video will come from the burn unit .

[@mirek6937]

Fuel fumes and hot iron. Sure it will fix Ur whole car and garage in second. Working in short tshirt no safety glasses.

[@DarrinTorrey1]

No arguments with any of that except that I was indeed wearing safety glasses... they are literally in my face at the start of the video. Also, I was working in the driveway. 😁

[@babyboi4778]

I used a face mask so I dont inhale the gas fumes or the plastic smell ..

[@DJizz82]

Still holding ?? Any leaks

[@DarrinTorrey1]

Still as good as the day I repaired it.

[@DarrinTorrey1]

3 years and still holding!

[@haroldharris7080]

J b weld dosen't work

[@DarrinTorrey1]

Not sure if this is a question, but I tried JB Plastic Weld first. It held for about a week before it started weeping again. I got under there and it peeked right off. I prepped the area as per the instructions.

[@joep9219]

I want to do it but I’m just afraid to blow up lol

[@FedWard.]

Update?

[@DarrinTorrey1]

It's working like a charm! Absolutely zero fuel smell. I was under the truck last weekend and it looks like the repair is holding up well.

[@gibby_gets_it]

Never worked for me, gas keeps sleeping through does not work

[@ed-venture7963]

hey man, I dont mean to troll you but everything about this from set up to safety and materials used was just wrong. posting this is dangerous as people may follow the bad practices and hurt themselves or others. I do appreciate the effort for making the film but this should really be an example of how NOT to do it. all the best going forward.

[@robertgriz2500]

Video and methods are perfectly fine You however cited nothing of relevance besides a worthless opinion. Not everything needs to be bubble wrapped for everyone. If you don't have a basic understanding of mechanics then you shouldn't touch a car period. If you choose to tinker anyways then accidents happen. If you don't think people would arguably try far more "dangerous" methods of repair without this man sharing his safer technique you're sadly mistaken.

[@ed-venture7963]

@@robertgriz2500 not bubble wrapped but done safely and effectively. Hopefully my worthless opinion might reach the people you haven’t considered. Stay safe everyone.

[@jhonsmith2150]

Nice job! But, DNT forget the safety goggles 🥽! Safety first! 🤙