1. Safety First!
* Empty and Clean: Completely empty the tank. This is crucial! Residual fuel is extremely flammable. Use a fuel siphon and appropriate safety precautions. Never attempt to work on a tank with any fuel remaining.
* Ventilation: Work in a well-ventilated area, preferably outdoors away from ignition sources. Gasoline fumes are dangerous.
* Safety Glasses & Gloves: Wear safety glasses and gloves throughout the entire process.
* Grounding: When handling the tank, especially during the sanding and painting stages, ensure you're grounded to prevent static electricity buildup which could ignite fuel vapors.
2. Tank Preparation:
* Thorough Cleaning: After emptying, thoroughly clean the inside and outside of the tank. A pressure washer can help, followed by solvent cleaning (using a product designed for this purpose). Pay close attention to removing any rust or debris.
* Rust Removal: Address any rust using a wire brush, sanding, or chemical rust remover. If the rust is extensive, professional tank repair or replacement might be necessary. Severe rust compromises the structural integrity of the tank.
* Surface Preparation: Once clean and rust-free, the surface needs to be perfectly smooth for proper paint adhesion. Use progressively finer grits of sandpaper (e.g., 180, 320, then 400 grit) to achieve a smooth finish. Consider using automotive-grade primer to help fill in minor imperfections.
* Degreasing: After sanding, thoroughly degrease the tank with a high-quality automotive degreaser. This removes any oils or contaminants that could prevent the paint from adhering properly.
3. Priming:
* Epoxy Primer: Apply several thin coats of a high-quality, self-etching epoxy primer specifically designed for metal. This is crucial for adhesion and corrosion resistance. Allow each coat to dry completely according to the manufacturer's instructions. This primer will help prevent future rust.
4. Painting:
* Automotive Paint: Use high-quality automotive-grade urethane or acrylic lacquer paint in your desired color. Multiple thin coats are better than one thick coat to prevent runs and ensure even coverage. Allow each coat to dry thoroughly.
* Clear Coat (Recommended): A clear coat is highly recommended to protect the paint from UV damage, chips, and scratches. Apply several thin coats and allow them to dry properly.
5. Baking (Optional but Recommended):
* Professional Baking: For the most durable finish, consider professional baking. This process cures the paint and primer properly for enhanced hardness and longevity. A body shop or specialized paint facility can do this.
6. Reinstallation:
* Inspect Carefully: Before reinstalling the gas tank, thoroughly inspect it for any damage or imperfections.
* Proper Installation: Install the tank according to the manufacturer's instructions. Ensure all fuel lines and connections are secure and leak-free.
Important Considerations:
* Professional Help: If you're not comfortable with any of these steps, especially rust repair or working with solvents and paints, consider seeking professional help from a body shop or automotive restoration specialist.
* Tank Sealing: If the tank has internal corrosion or requires significant repair, it might require professional sealing or epoxy liner application to prevent future leaks.
Painting a gas tank correctly is a significant undertaking. It requires patience, attention to detail, and an understanding of safety procedures. Taking shortcuts can lead to a poor finish, safety hazards, and potentially dangerous fuel leaks. The extra effort invested in proper preparation will yield a far superior and safer result.
