Fuel tank dent repair

[Sams Outboard]

Hey folks. I was curious what some of you guys do to repair a fuel tank that’s badly dented. What I’ve done is used compressed air to try and remove some of the dents. Then use body filler in thin layers to fill in the remaining dents. The photo shows the front of the tank. Though there was plenty of dents on the sides too

[labrador-guy]

Sam you have that tank looking good!   As for dent removal you name it somebody has probably done it.  I have had to cut a hole on the inside a couple times, bump out the dent and then get the hole in the tank welded.   I have many motors around here that I call Lumpy!  Previous owners must have thrown the old kickers around like a football.   Some members like to polish the aluminum to look like chrome.   I am too lazy for that.  Good luck with your paint.

dale

[Sams Outboard]

Hey there thanks for the reply! This tank was just a mess and this is the first fill restoration I’ve done. I didn’t really know if I was doing things the “traditional way” but good to hear I was on the right track. The paint color I used isn’t a perfect match but it’ll do for me. I’m using this particular project as a learning experience for future restorations on what to do and what not to do. The photo I put is what it looks like now. There’s a spot on the other side where the paint underneath the clear rippled a little. That was my own mistake. All good though

[Tubs]

Much of what I can do I learned by doing it including
removing dents from gas tanks. The tanks on the
motors I have repaired are mostly square. Simple
compared to your tank. Mostly curved but still flat on
top. And then there are those straight lines. Yikes!
That’s quite an accomplishment for your first attempt.
You done good.
Tubs.

A "Boathouse Repair" is one that done without having tools or the skills to do it properly.

[Buccaneer]

I have a few tanks to send you for repair!
Compressed air can be a great aid in removing dents, but
be aware if you try it on a rectangular tank…….. they could
end up “round” in a hurry!

Prepare to be boarded!

[Bob Wight]

Nice job, looks good!  If you do lots of these, you’ll find that Bondo is your friend.

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1955 Johnson QD-16
1957 Evinrude Fastwin 18
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

• This reply was modified 2 years, 10 months ago by Bob Wight.

[brianlejeune]

Awesome job. You must have been an auto body repair guy in your early life.

Brian

1947 - 2.5 hp Sears Elgin
1973 - 6 hp Evinrude (Fisherman)
1981 - 9.9 Evinrude

[Sams Outboard]

Hah I wish I was. I’m actually 15 this is the first “full” restoration I’ve done

[Sams Outboard]

Thank you! It still isnt perfect but like I mentioned before I using this as a learning experience

• This reply was modified 2 years, 10 months ago by Sams Outboard.

[Sams Outboard]

Your saying you want me to fix them up?

[Author]

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