fuel tank project

maxle601 · 03-20-2005, 09:42 AM

I have decided to take the fuel tank out of my 72 911S and clean it and paint it and replace the sender. This project does not seem to be in Wayne's book.Looking into the tank it seems to have a few rust spots but not much. Does anyone know what the process is... I heard al ittle about POR15 What is the correct paint for the early steel tanks. What kind of seal replacement? Thanks for the help in advance

Maxle601

real550A · real550A's Garage

Having just completed this project, I can offer a little insight.
My tank had more rust than you described, so I did the "boil out" first. If your tank just has minor rust spots, I wouldn't worry-almost every steel tank has them.
To prevent further rust, try to avoid gasoline containing alcohol (such as ethanol). It attracts water from the atmosphere.
You can use quality foam tape (I used cap tape for a pickup) and 3M weatherstrip adhesive for the seal.
Replacing the sender is forthright. New gasket may be needed.

This is a sender after 18 years in a barn!

Nitrometano · Nitrometano's Garage

I do this to my 911 72.
Remove the tank and clean in with gas to remove all the rust debris inside. Then I put 2 cycle oil into the tank to seal out the rust spots from the ambient for the time that I paint the tank. I dont use the foam seal. I just buy caulk and put it around the tank hole. Also buy a new fuel filter.

Good luck.

03-20-2005, 11:52 PM

Here are pics from my late model Carrera tank that I restored into my 73 RS. Inside was in good shape so I left it alone. I POR-15 the edges and the bottom. Then I painted the bottom Rustolium black and the top grey. Its an oil based paint and adheres to the rubber coating well. Just clean the tank with Castrol purple cleaner first and degrease it first. Make sure you wear gloves because it can dry out your hands pretty well!

I also went to Home Depot and got some 3/8 foam weatherstriping tape to seal the bottom of the tank. It came out great.