There’s a Hole in the Gas Tank!

The Karmann Ghia has a hole in the gas tank! In the newest installment of the dream car series, Bob has to refurbish the Karmann Ghia’s gas tank with a product he’s never used before. Come see how it went!

1. Fuel Tank Coating Solution
2. Plug Any Holes
3. Install the Fuel Tank

1. Fuel Tank Coating Solution

When I purchase this 1970 Volkswagon Karmann Ghia, it was drawing fuel out of a modified plastic bottle. The gas tank had been removed and it was in pretty bad shape. I knew that in order to install the fuel tank properly, I was going to have to clean and resurface the inside. To do this, there is a fuel tank sealing kit that comes in three parts; a cleaning solution, a priming wash, and an epoxy coating layer. Each of these separate processes need to done in an awkward way. You have to slosh them around evenly inside the fuel tank. So, make sure you are able to hold the tank and spin it around after covering the holes.

2. Plug Any Holes

During the coating process, I discovered that I had a hole in the top of the fuel tank. Luckily, I was able to take of the epoxy coating layer and paint it over the hole. The combination of the interior coating layer and this supplemental outer layer sure be enough to plug the hole. The gas tank has other purposeful holes. There’s one for the fill hose, one for the supply line that had a threaded elbow, and one large one for the sending unit. The sending unit tells the car how much fuel is in the tank. It has a metal probe that needs a gasket before installation. You should always order the right part for the right application, but I was able to find some sheets of gasket material that I cut into the right shape.

3. Install the Fuel Tank

At this point, I was able to cut some temporary foam to act as padding and install the fuel tank. I had issues with tank’s supply line fitting, which I’ve already ordered. For now, it will be ok. The point of this project is to clean and coat the gas tank. I mounted it in the car to test it and to drive it out to the farm. Besides the coating, all of the installation work will be temporary. I further plan on tearing the entire car down and rebuilding it section by section at the farm. But for now, the gas tank works and the car runs!