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Old 02-05-2007, 02:45 PM   #1
a1autosports
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Default Punctured gas tank! need instructions on removal

It sounds stupid but I accidently mounted a stereo fuse box underneath my rear seat and I didn't know that I was actually drilling into part of the fuel tank! Now I have to remove it, reweld it and put it back on. Does anyone have ANY instructions on removing the ENTIRE fuel tank? Any help would be appreciated.
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Old 02-05-2007, 03:36 PM   #2
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Wow.. theres a first time for everything i guess!

You might need a shop manual, or to go to a mechanic or even a subaru dealer with your car. If your going to do it yourself you should see if there are instructions even general instructions on how to do this. There is significant risk if you do this wrong Im sure you know so do some research first. Sorry I cant help you bro.

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Old 02-05-2007, 04:39 PM   #3
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You accidentally mounted a fuse box?
Dude, take it somewhere and have it fixed. Do not attempt to weld a gas tank yourself unless you are trained in these things. Gas fumes go boom, kapisch?
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Old 02-05-2007, 05:08 PM   #4
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Get a couple of quotes.
For fixing the tank by trained personnel or replacing it, again, by trained personnel.
Neither one of the above options are for the do it yourself guy, it is way harder and way, way more dangerous, than it sounds. The reason I say that is because I read the TSB for removing/replacing the gas tank for the MY05 Nissan Sentra, that I used to own, not the same as Subaru, but the difficult and dangerous issues still apply.

Last edited by joecerv; 02-05-2007 at 05:13 PM.
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Old 02-06-2007, 03:03 AM   #5
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This is not the end of the world really. I own a car dealership and have repaired 2 tanks like this in the last year. First remove fuel from the tank using a sciphon method. Second drop the tank. Third sand with hand sand paper around the hole. Fourth seal with a fuel resistant epoxy available at most major car part chains. Fith re-install tank. Trust me this SUCKS time wise but it does work. CB!
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Old 02-06-2007, 10:22 AM   #6
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JB weld ftw!
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Old 02-06-2007, 11:28 AM   #7
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You have to remove the rear diff among other things to change out the fuel tank- major PITA.


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Old 02-10-2007, 01:09 AM   #8
a1autosports
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Hmmm....the holes are less than a 1/8in in diamater and I can see them from right under the back seat, I wonder if I can squirt the fuel resistant epoxy right from there to fill the holes?
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Old 02-10-2007, 04:26 PM   #9
Mike Wevrick
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Or you could put small screws into the holes to seal them
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Old 02-10-2007, 04:40 PM   #10
Alan
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Using a screw with some epoxy on the threads might be an acceptable repair. I think he might want to make a bigger hole (CAREFULLY) in the body so he can get the screw head to seal against the tank, and use a short (1/4 to 1/2") shoulder screw that would seat against the tank. With epoxy, a flat surface of the screw glued to the tank top, and glued screw threads it ought to be as good as needed - and very easy to do.
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Old 02-10-2007, 11:26 PM   #11
a1autosports
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would getting this epoxy into the gasoline affect it at all?
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Old 02-11-2007, 12:32 AM   #12
Alan
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If you mean once the epoxy dries and hardens, will gasoline affect it - the answer is no. If you drop the mixed epoxy into the tank, I suppose it could be affected by the gasoline, and maybe little bits of it would find their way to the fuel filter. I'd recommend doing the repair with less than 3/4 tank of gas to be sure to not have gasoline wetting the top of the tank, and letting it cure for a couple of hours before driving. Just to be sure.
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Old 02-11-2007, 01:38 AM   #13
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thanx for the help! I love NASIOC
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