How successful is cleaning and resealing existing fuel tank? It's cheaper to clean/reseal. What have you used to clean/reseal? I'm looking at using the POR 15 fuel tank kit.

How is fit and durability of new? There are only two options on rock auto for me, 17g Carb., Dorman and Spectra Premium. Both painted.

 

it depends on the product used

 

My friend use por15 tank kit on a POS VW bug tank and it seemed to work.
It was rusted to hell on the inside. i wanted to remove the barrel from my cement mixer and strap the tank to that, then try various media (gravel, sand, shot gun bb's etc) while it turned, but he was worried it might create a hole.

 

Love the cement mixer idea! Sure would faster and cheaper than soaking in whatever solution is supposed to work.

I watched a youtube video where a guy fills a tank with white vineger, a quick swish of muriatic acid and then coats using a Caswell product. He showed big rust chunks that came out after the vinegar soak. So I did a little test overnight. I soaked three truck bed bolts: one in white vinegar, one in evapo-rust, and one in oxalic acid. The vinegar and oxalic took off light rust and only a few spots of heavy rust in 24hrs. I might not have had a strong enough acid solution though. The evapo-rust did a great job getting thick rust off. Using 17 g of evapo-rust is cost prohibitive.

I'm asking about the fuel tank because I need to replace the sender. I won't be able to just replace the sender if I look in the tank and see crud.

 

I got lucky! There are only two spots of rust that I can see in my tank. One is about a dime size the other maybe a 50 cent size.

 

when i did this, i hung the tank from beams in the garage, using bungee cords, so i could put gravel in the tank along with the solution, to bounce it around and break up the rust... also have to remove any traces of petroleum products, or the sealer may not stick.

in the end it wasn't worth the hassle, if i could have gotten a new tank i would have done it.

 

I put a dorman tank in mine. There was an area on the flange I had to remove a small amount of material from with the grinder but otherwise it dropped right in and so far no issues.