After many off road camping trips over the past 15 years, the diesel tank on my MK1 developed a 50 mm long crack on the bottom. A fair bit of deformation had taken place.
Knowing more off roading will at least flex any repair, I removed the tank, washed it and had the crack gas welded, inside and outside.
The repair is sound after a recent 8400 km Namibia trip, I do think the repair is as sound as the remaining tank bottom.
Silverton Radiators recently welded a patch on my Gen 1 diesel fuel tank. A stone had lodged between the outer protective sleeve and the tank itself. This gradually wore a small hole in the tank. Diesel is not regarded as inflammable and the steel tank can be welded easily.
A very useful trick for a petrol tank with a hole is to buy a block of sunlight soap (as fresh as possible so that it is not too hard) and layer that round the hole. A few drops of water help to get the soap to sick. I ran a saloon Taunus for years with a fist size hole in the tank which I repaired with soap. Dust and dirt collect on the soap surface and help to protect it!
I found to my regret, that soap will not fix a diesel tank, the soap dissolves in diesel oil and you soon have the leak back again.
A very useful trick for a petrol tank with a hole is to buy a block of sunlight soap (as fresh as possible so that it is not too hard) and layer that round the hole. A few drops of water help to get the soap to sick. I ran a saloon Taunus for years with a fist size hole in the tank which I repaired with soap. Dust and dirt collect on the soap surface and help to protect it!
I found to my regret, that soap will not fix a diesel tank, the soap dissolves in diesel oil and you soon have the leak back again.
1986 Mark 1 Pajero 2.5L turbo diesel station wagon
1993 220si Toyota Camry saloon auto
1993 220si Toyota Camry saloon auto
For very strong glue, put baking soda mildly over both materials to be glued, drop any superglue onto the baking soda. It sets very fast and very strong. Same as Q-Bond, just stronger and cheaper and you can take permanent marker to color it. I do not know if this will fix your tank problem, but try it on any other plastic parts you want to glue.cloyd wrote:Karl,
Silvertons in Koedoespoort do cleaning of fuel tanks @ approx. R400,00 per tank. It takes about two days. I assume that they can also do repairs. My recommendation will still be PRATLEYS putty and some elbow grease. (no baking soda! PRATLEYS makes a similar product as Q-bond - POWDA BOND - and according to Kim it is a better product.
Cloyd
Tried the pratley putty... did not want to stick. Even using spirits to wipe it clean. It sticks on for a few mins, but eventually falls off 
Will attempt it one more time, otherwise will have to go to silverton
Will attempt it one more time, otherwise will have to go to silverton
Karl
Karl,
Maybe it is a case of "dirty fingers"? My sump repair is still working as if it came out of the factory like that.
Cloyd
Maybe it is a case of "dirty fingers"? My sump repair is still working as if it came out of the factory like that.
Cloyd
Changed my cracked tank at last.
Here's a proof of my incredible suggestion to use silicone (!) to seal that classic pajero tank crack. It must be windscreen silicone.
The silicone lasted for 3 years, & still looks ok!
Here's a proof of my incredible suggestion to use silicone (!) to seal that classic pajero tank crack. It must be windscreen silicone.
The silicone lasted for 3 years, & still looks ok!