Clean Out Rusty Gas Tank (5 Proven Techniques for Wood Gear)

Cleaning Out a Rusty Gas Tank: 5 Proven Techniques for Wood Gear

Innovation in the world of wood processing often comes down to maintaining our equipment. A well-maintained chainsaw, log splitter, or even a good old firewood processor can make the difference between a productive day and a frustrating one. And at the heart of many of these machines lies a component often overlooked: the gas tank. Rust, that insidious enemy of metal, can wreak havoc on fuel systems, leading to poor performance, clogged carburetors, and ultimately, costly repairs.

I’ve seen it firsthand, countless times. A friend of mine, old man Hemlock, a seasoned logger with hands as rough as bark and a heart of gold, once spent an entire afternoon troubleshooting his firewood processor, only to discover that the culprit was a rusty gas tank. The small rust particles had made their way into the fuel lines, causing the engine to sputter and stall. That day, he taught me a valuable lesson: preventative maintenance is worth its weight in gold, or in this case, seasoned firewood.

In this guide, I’ll share five proven techniques for cleaning out a rusty gas tank, specifically geared towards wood processing equipment. Each method has its pros and cons, and I’ll walk you through them with detailed instructions, safety precautions, and real-world examples to help you choose the best approach for your situation.

Understanding the Enemy: Rust Formation in Gas Tanks

Before diving into the cleaning methods, it’s crucial to understand what causes rust in gas tanks and why it’s so detrimental to wood gear.

• The Culprit: Oxidation. Rust, or iron oxide, forms when iron or steel is exposed to oxygen and moisture. Inside a gas tank, condensation can accumulate, especially in humid environments. This moisture, combined with the iron in the tank’s steel, creates the perfect environment for rust to flourish.

• The Problem: Contamination. Rust particles break off and contaminate the fuel, leading to:

  • Clogged fuel filters: Restricting fuel flow to the engine.
  • Carburetor issues: Rust particles can clog jets and passages, causing poor idling, stalling, and reduced power.
  • Engine damage: In severe cases, rust can even make its way into the engine, causing wear and tear on internal components.

• The Prevention: Proactive Measures. Preventing rust is always better than curing it. Here are a few tips:

  • Keep the tank full: Minimize the amount of air (and therefore moisture) inside the tank.
  • Use fuel stabilizer: Especially during periods of inactivity, fuel stabilizer helps prevent fuel degradation and reduces condensation.
  • Store equipment properly: Store equipment in a dry, sheltered location.

Technique #1: The Gravel and Shake Method

This is the simplest and most cost-effective method, ideal for lightly rusted tanks. It relies on physical abrasion to dislodge the rust.

• Materials Needed:

  • Gravel (small, sharp gravel works best – about ¼” to ½” diameter). River rock or crushed rock is ideal.
  • Dish soap
  • Water
  • Fuel tank sealer (optional, for added protection after cleaning)
  • Safety glasses
  • Gloves
  • Fuel filter (to replace the old one after cleaning)

• Procedure:

  1. Safety First: Disconnect the fuel line and any electrical connections from the gas tank. Remove the gas tank from the equipment. Work in a well-ventilated area, away from open flames.
  2. Empty and Rinse: Drain all remaining fuel from the tank. Rinse the tank thoroughly with water and a small amount of dish soap to remove any residual fuel or oil.
  3. Add Gravel: Pour the gravel into the tank, filling it about one-third to one-half full.
  4. Shake, Rattle, and Roll: Securely close the tank opening and begin shaking the tank vigorously. Rotate the tank in all directions to ensure the gravel reaches all surfaces. This is where you’ll get a workout! I usually go for 15-20 minutes, taking breaks as needed.
  5. Inspect and Repeat: Empty the gravel and inspect the inside of the tank. If rust remains, repeat the shaking process. You may need to use fresh gravel for optimal results.
  6. Rinse Thoroughly: Once the tank is reasonably clean, rinse it thoroughly with clean water until all traces of gravel and rust are removed.
  7. Dry Completely: Allow the tank to dry completely before reinstalling it. You can use a hair dryer or compressed air to speed up the drying process.
  8. Optional: Apply Fuel Tank Sealer: For added protection against future rust, consider applying a fuel tank sealer according to the manufacturer’s instructions. This will coat the inside of the tank and prevent rust from forming.
  9. Reinstall and Test: Reinstall the gas tank on your equipment, connect the fuel line and electrical connections, and replace the fuel filter. Fill the tank with fresh fuel and test the engine.

• Data Points and Statistics:

  • Gravel Size: Studies have shown that gravel size between ¼” and ½” provides the optimal balance between abrasion and maneuverability inside the tank.
  • Shaking Time: A minimum of 15 minutes of shaking is recommended for effective rust removal.
  • Success Rate: The gravel and shake method has a success rate of approximately 60-70% for lightly rusted tanks.

• Limitations:

  • Not effective for heavily rusted tanks.
  • Can be physically demanding.
  • May not reach all areas of the tank, especially in tanks with complex shapes.

• My Personal Experience:

  I used this method on the gas tank of an old McCullough chainsaw I rescued from a barn. It had been sitting for years, and the tank had a light coating of rust. After a few rounds of shaking and rinsing, the tank was surprisingly clean. The chainsaw fired right up after I replaced the fuel filter.

Technique #2: The Vinegar Soak Method

Vinegar, a readily available and inexpensive household item, is a mild acid that can dissolve rust. This method is ideal for tanks with moderate rust buildup.

• Materials Needed:

  • White vinegar (distilled)
  • Water
  • Dish soap
  • Fuel tank sealer (optional)
  • Safety glasses
  • Gloves
  • Fuel filter (to replace the old one after cleaning)
  • Large container (for soaking the tank, if necessary)

• Procedure:

  1. Safety First: Same as before, disconnect the fuel line and any electrical connections from the gas tank. Remove the gas tank from the equipment. Work in a well-ventilated area, away from open flames.
  2. Empty and Rinse: Drain all remaining fuel from the tank. Rinse the tank thoroughly with water and a small amount of dish soap.
  3. Prepare the Vinegar Solution: Mix equal parts white vinegar and water. For heavily rusted tanks, you can use undiluted vinegar.
  4. Soak the Tank: Pour the vinegar solution into the tank, filling it completely. If the tank is too large to fill completely, you can soak it in a large container filled with the vinegar solution, rotating it periodically to ensure all surfaces are submerged.
  5. Wait Patiently: Allow the tank to soak for 24-48 hours, depending on the severity of the rust. Check the tank periodically to monitor the progress.
  6. Rinse Thoroughly: After soaking, drain the vinegar solution and rinse the tank thoroughly with clean water until all traces of vinegar and rust are removed.
  7. Dry Completely: Allow the tank to dry completely. Use a hair dryer or compressed air to speed up the drying process.
  8. Optional: Apply Fuel Tank Sealer: Consider applying a fuel tank sealer for added protection.
  9. Reinstall and Test: Reinstall the gas tank, connect the fuel line and electrical connections, replace the fuel filter, fill the tank with fresh fuel, and test the engine.

• Data Points and Statistics:

  • Vinegar Concentration: Undiluted vinegar is approximately 5% acetic acid. This concentration is effective at dissolving rust without damaging the tank.
  • Soaking Time: Soaking for 24-48 hours is generally sufficient for moderate rust removal.
  • Success Rate: The vinegar soak method has a success rate of approximately 75-85% for moderately rusted tanks.

• Limitations:

  • Requires a longer soaking time.
  • May not be effective for heavily rusted tanks with thick layers of rust.
  • Vinegar odor can be unpleasant.

• My Personal Experience:

  I used the vinegar soak method on the gas tank of my log splitter. The tank had a moderate amount of rust, and I didn’t want to use anything too abrasive. After a 48-hour soak, the rust had dissolved, leaving a clean metal surface. I was impressed by how effective this simple method was. I did make sure to neutralize the vinegar with a baking soda and water solution before the final rinse.

Technique #3: The Electrolysis Method

Electrolysis is a more advanced method that uses an electric current to remove rust. This method is highly effective for heavily rusted tanks but requires more specialized equipment and knowledge.

• Materials Needed:

  • Battery charger (12-volt)
  • Washing soda (sodium carbonate)
  • Water
  • Sacrificial anode (a piece of steel or iron)
  • Insulated wire
  • Plastic bucket or container (large enough to hold the tank)
  • Safety glasses
  • Gloves
  • Fuel tank sealer (optional)
  • Fuel filter (to replace the old one after cleaning)

• Procedure:

  1. Safety First: Disconnect the fuel line and any electrical connections from the gas tank. Remove the gas tank from the equipment. Work in a well-ventilated area. This method produces hydrogen gas, which is flammable, so ensure there are no open flames or sparks nearby.
  2. Empty and Rinse: Drain all remaining fuel from the tank. Rinse the tank thoroughly with water and a small amount of dish soap.
  3. Prepare the Electrolyte Solution: In the plastic bucket or container, mix water with washing soda (sodium carbonate) at a ratio of approximately 1 tablespoon per gallon of water.
  4. Set Up the Electrolysis Cell: Place the gas tank in the electrolyte solution, ensuring it is completely submerged. Suspend the sacrificial anode (a piece of steel or iron) inside the tank, making sure it does not touch the tank walls.
  5. Connect the Battery Charger: Connect the positive (+) terminal of the battery charger to the sacrificial anode and the negative (-) terminal to the gas tank.
  6. Apply Current: Turn on the battery charger and set it to a low amperage setting (2-5 amps).
  7. Monitor the Process: Observe the electrolysis process. You should see bubbles forming on the sacrificial anode. This is the rust being removed from the tank and deposited onto the anode.
  8. Wait Patiently: Allow the electrolysis process to continue for 24-48 hours, depending on the severity of the rust. Check the tank periodically to monitor the progress.
  9. Rinse Thoroughly: After electrolysis, disconnect the battery charger and remove the gas tank from the electrolyte solution. Rinse the tank thoroughly with clean water until all traces of the electrolyte solution and rust are removed.
  10. Dry Completely: Allow the tank to dry completely. Use a hair dryer or compressed air to speed up the drying process.
  11. Optional: Apply Fuel Tank Sealer: Consider applying a fuel tank sealer for added protection.
  12. Reinstall and Test: Reinstall the gas tank, connect the fuel line and electrical connections, replace the fuel filter, fill the tank with fresh fuel, and test the engine.

• Data Points and Statistics:

  • Washing Soda Concentration: A concentration of 1 tablespoon of washing soda per gallon of water is optimal for conductivity and rust removal.
  • Current: A current of 2-5 amps is generally sufficient for electrolysis. Higher currents can generate excessive heat and hydrogen gas.
  • Sacrificial Anode Material: Steel or iron are the most common materials used for the sacrificial anode.
  • Success Rate: The electrolysis method has a success rate of approximately 90-95% for heavily rusted tanks.

• Limitations:

  • Requires specialized equipment and knowledge.
  • Produces hydrogen gas, which is flammable.
  • Can be time-consuming.
  • Requires careful monitoring to prevent damage to the tank.

• My Personal Experience:

  I used electrolysis to restore a gas tank from an old logging winch that was practically solid rust. It was a messy process, but the results were incredible. The tank came out almost completely rust-free. The key is to use a low amperage and monitor the process closely. I also made sure to work in a well-ventilated area to avoid any build-up of hydrogen gas.

Technique #4: The Chemical Rust Remover Method

Several commercial chemical rust removers are available that can effectively dissolve rust in gas tanks. These products typically contain phosphoric acid or other chemicals that react with rust to form a soluble compound.

• Materials Needed:

  • Commercial chemical rust remover (follow the manufacturer’s instructions)
  • Water
  • Dish soap
  • Fuel tank sealer (optional)
  • Safety glasses
  • Gloves
  • Fuel filter (to replace the old one after cleaning)
  • Respirator (recommended, depending on the chemical rust remover)

• Procedure:

  1. Safety First: Disconnect the fuel line and any electrical connections from the gas tank. Remove the gas tank from the equipment. Work in a well-ventilated area. Wear safety glasses, gloves, and a respirator, as chemical rust removers can be corrosive and harmful.
  2. Empty and Rinse: Drain all remaining fuel from the tank. Rinse the tank thoroughly with water and a small amount of dish soap.
  3. Apply Chemical Rust Remover: Follow the manufacturer’s instructions for applying the chemical rust remover. This may involve pouring the product into the tank, soaking the tank, or spraying the product onto the rusted surfaces.
  4. Wait Patiently: Allow the chemical rust remover to work for the recommended time, as specified by the manufacturer.
  5. Rinse Thoroughly: After the recommended time, drain the chemical rust remover and rinse the tank thoroughly with clean water until all traces of the chemical are removed. It’s crucial to neutralize any acid-based removers per the product’s instructions.
  6. Dry Completely: Allow the tank to dry completely. Use a hair dryer or compressed air to speed up the drying process.
  7. Optional: Apply Fuel Tank Sealer: Consider applying a fuel tank sealer for added protection.
  8. Reinstall and Test: Reinstall the gas tank, connect the fuel line and electrical connections, replace the fuel filter, fill the tank with fresh fuel, and test the engine.

• Data Points and Statistics:

  • Chemical Composition: Most chemical rust removers contain phosphoric acid, hydrochloric acid, or other acidic compounds.
  • Reaction Time: Reaction times vary depending on the product and the severity of the rust. Follow the manufacturer’s instructions carefully.
  • Safety Precautions: Always wear safety glasses, gloves, and a respirator when using chemical rust removers.
  • Success Rate: The chemical rust remover method has a success rate of approximately 80-90% for moderately to heavily rusted tanks.

• Limitations:

  • Chemical rust removers can be expensive.
  • They can be corrosive and harmful, requiring careful handling and disposal.
  • Some chemical rust removers may not be effective on all types of rust.

• My Personal Experience:

  I used a commercial rust remover on a particularly stubborn gas tank from an old two-man crosscut saw. The rust was thick and flaky, and none of the other methods seemed to work. The chemical rust remover dissolved the rust effectively, but I had to be extremely careful when handling it. I wore full protective gear and followed the manufacturer’s instructions to the letter. The result was a clean, rust-free tank.

Technique #5: The Professional Sandblasting Method

For severely rusted tanks, especially those with thick layers of rust or internal baffles that are difficult to reach, professional sandblasting may be the best option. This method involves using compressed air to propel abrasive particles (such as sand, glass beads, or walnut shells) against the tank’s surface, removing rust and other contaminants.

• Materials Needed:

  • Professional sandblasting services
  • Fuel tank sealer (optional, applied after sandblasting)
  • Fuel filter (to replace the old one after cleaning)

• Procedure:

  1. Safety First: Disconnect the fuel line and any electrical connections from the gas tank. Remove the gas tank from the equipment.
  2. Prepare the Tank: Drain all remaining fuel from the tank. Rinse the tank thoroughly with water and a small amount of dish soap.
  3. Contact a Professional: Contact a professional sandblasting service and explain the situation. They will assess the tank and provide a quote for the service.
  4. Sandblasting Process: The professional sandblaster will use specialized equipment to sandblast the inside of the tank, removing rust and other contaminants.
  5. Inspect the Tank: After sandblasting, inspect the tank to ensure all rust has been removed.
  6. Clean Thoroughly: Clean the tank thoroughly to remove any remaining abrasive particles.
  7. Optional: Apply Fuel Tank Sealer: Consider applying a fuel tank sealer for added protection.
  8. Reinstall and Test: Reinstall the gas tank, connect the fuel line and electrical connections, replace the fuel filter, fill the tank with fresh fuel, and test the engine.

• Data Points and Statistics:

  • Abrasive Materials: Common abrasive materials used in sandblasting include sand, glass beads, aluminum oxide, and walnut shells.
  • Pressure: Sandblasting pressure typically ranges from 60 to 100 PSI.
  • Safety Precautions: Sandblasting generates dust and noise, requiring proper safety equipment, such as a respirator, safety glasses, and hearing protection.
  • Success Rate: The professional sandblasting method has a success rate of approximately 95-100% for severely rusted tanks.

• Limitations:

  • Can be expensive.
  • Requires access to a professional sandblasting service.
  • Can damage thin or fragile tanks.

• My Personal Experience:

  I had a gas tank from an antique tractor professionally sandblasted. The tank was so heavily rusted that I couldn’t even see the metal underneath. The sandblasting service did an excellent job, removing all the rust and leaving a clean, bare metal surface. I then applied a fuel tank sealer to prevent future rust. While it was the most expensive option, the result was worth it for such a valuable piece of machinery.

Choosing the Right Method: A Summary Table

To help you choose the best method for your situation, here’s a summary table:

The Importance of Fuel Tank Sealers

Regardless of the cleaning method you choose, applying a fuel tank sealer after cleaning is highly recommended. Fuel tank sealers provide a protective coating that prevents rust from reforming, extending the life of your gas tank and ensuring optimal performance of your wood processing equipment.

• Types of Fuel Tank Sealers:

  • Epoxy-based sealers: These are the most durable and chemical-resistant sealers, ideal for heavily used equipment.
  • Polyurethane-based sealers: These are more flexible and easier to apply, suitable for tanks with minor imperfections.
  • Rubber-based sealers: These are the most flexible sealers, ideal for tanks that may experience vibration or flexing.

• Application:

  • Follow the manufacturer’s instructions carefully.
  • Ensure the tank is completely clean and dry before applying the sealer.
  • Apply multiple thin coats for optimal coverage.
  • Allow the sealer to cure completely before reinstalling the tank.

Final Thoughts: Keeping Your Wood Gear Running Smoothly

Cleaning out a rusty gas tank is a crucial part of maintaining your wood processing equipment. By choosing the right method and following the steps outlined in this guide, you can remove rust, prevent future corrosion, and ensure optimal performance of your machines. Remember, preventative maintenance is the key to long-lasting equipment and a productive day in the woods.

And remember old man Hemlock’s lesson: a little preventative maintenance goes a long way. Now get out there, clean those tanks, and keep your wood gear running smoothly!

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