Pajero Owners Club of South Africa

This is something likely caused by one of my early 4x4 play sessions before I had the lift done (and where I cracked the plastic cover over the fuel tank).

The crack on the bottom of the tank is so small that the mechanics missed it and initially thought it was coming from somewhere else.

The amount leaked is very small - I dont even notice it on fuel consumption, you just always see a few drop below the car and can sometimes smell diesel if the car has been standing for a while.

Now there are 2 options:

1. Order tank from Japan - waiting period 1... cost of about R9k + more labour costs taking it up to close to R11k (I will probably just order the tank and have an indi install it)

2. As this is a metal tank, surely it can be patched/welded? I suggested to Mitsu maybe a panel beater, but they reckoned there are specialists out there who would be better to use... Any recommendations?

Given the leak is so slow, I'm happy to sit around for a while and determine the best option, rather than blowing R11k on something fairly small.

(Maybe I can also get my cracked cover plastic welded when I'm at the 'specialist'? )

The problem with any welding done on a tank is that they need to take the tank out and completely drain and wash it otherwise - Kaboom! Usually the OEM metal tanks cannot be repaired as they are just too thin and gets chucked away. Maybe consider a new tank made up by a tank builder that can also incorporate an aux tank. It will cost less than the OEM one.

If it is only a small crack I will try Pratley-Steel mix as a first try. I have fixed an auxilary fuel with this stuff and so far so good.

It is a lot cheaper than a new tank and worth a try.


CATS

Fantastic... pratley here I come.

Only tank builder I know of is Cloyd... Keen for a new project?

Otherwise, anybody have any other references?

Karl,

My suggestions:

a. Buy a second hand tank and install. My tank was badly dinged in the Namib so I replaced it with a second hand one. Cost: R1400 plus my own labour and time.

b. Use PRATLEYS putty. I repaired my Audi's aluminium sump with PRATLEYS - it was cracked when I rode over some rubbish laying on the freeway. I know Kim Pratley from our flying activities and he gave me some tips on how to make the putty really stick.

c. Third option: Make a new tank. I also considered doing it but the top of the Pajero tank is shaped so that it fits in with the contour of the floor. Making a tank is possible but I doubt it if the "maker" will be able to shape it so that he will get 90 litres of fuel in it.

As an extra: My spare wheel bracket is installed and works as it should - I even use my spare wheel lock. Lift 52 mm and I might be able to get a few mm more lift.

Cloyd

I know this might sound a bit strange, but try asking at your local radiator repair shop (Silverton...). I know that the local branch do cleaning of fuel tank internals and they are used to working with thin materials.

Anyway, no harm in asking them.

Otherwise a specialist welding shop.

Thanks - will try a silverton

Cloyd - making the prayley stick - would it involve baking soda?

Do share the tips!!

Ja - also immediatly thought of pratley steel - should fix it without any problems.

Hi
As this is only a hairline crack as you described, i recommend Q-BOND. I have used this product on virtually all materials and find it excellent.You just have to follow the simple instructions but very important is to ensure that the area to be repaired is clean and dry. Also roughen up the area a bit to ensure better adhesion.
Regards
Keith

tried the pratley steel (twice): didn't stay stuck, despite precautions. what is the 'baking soda' trick?

then tried windscreen silicone sealer, and it's been ok for a year (believe it!)

in meantime bought a used tank from Part Hunt; when the silicone begins to leak, will install the tank.

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