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Contact us on 07778 265 726 or
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NoR CEL
Horrors of Badly Applied/Unsuitable Lining
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This lining was removed from a Triumph T500 tank that had been lined with the old Polyester resin that is not proof against the Ethanol in modern pump petrol.  The lining had been applied over a rusty surface as can be seen by the rust flakes sticking to the resin in the first picture. A larger picture of the rust flake is shown below.  This badly prepared surface does not allow the resin to fix itself to the surface and make a complete, protective envelope inside the tank. 
Also the resin, after being slosh applied inside the tank was allowed to settle on the bottom and created a thick layer taking up space needed for the petrol and causing the following problems. The thickness removes the flexibility of the resin and does not allow it to absorb impact shock or cope with the vibration of the tank in normal use. This can cause cracks in the lining where the Ethanol petrol can seep through and attack the metal surface causing new rust. This in time will cause the lining to delaminate from the tank and the rust will perforate the tank causing leaks
Another Triumph tank brought in from America.  My client, finding it near impossible to source a tank of this style in Europe, decided to purchase one advertised in the USA.  On arrival he noticed that the inside had a lining that had failed and allowed rust to establish itself to a severe level.
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On looking inside the tank it was obvious that some of the lining had come loose and in other areas it was attached but lifting. Also the bike had stood for some time with the petrol cap off the rust was more noticeable on the frame tube hump and by looking in with a videocam it was apparent that some heavy rusting had started on the floor of the tank and in the petrol feed outlet areas.  
The lining had to be removed before any de-rusting could take place.  A chemical was introduced to melt or soften the resin of the tank sealer.  It took some time for the lining to come free and then it was a question of extracting it piece by piece. It required two sessions of chemical soak before all the lining could be removed.
The tank then went into final preparation and was sealed with Caswell's GTS 1750 Phenol Novolac Amine Resin.

Phenol Novolac Epoxies are a new breed of chemical resistant materials, able to withstand permanent immersion of many harsh solvents,fuels and oils. This Epoxy has much better bond strength than single component products, with strengths of up to 3000 PSI, and this higher strength reduces the need for a clinically clean surface, as the epoxy actually prefers to bond to a rough surface often created by rust.. The new phenol novolac is more thixotropic, which means it ‘hangs’ on the tank walls during the coating process. This gives a thicker overall coating. 
It can be so much better to have a tank restored in this way and maintain its originality than to buy a new replacement part. Some tanks are irreplaceable and in the case of Vintage items have to be made from scratch.

For example: to replace a petrol tank on a 1954 MG TF the cost would be approximately £450.00 plus VAT giving an initial outlay of £540.00.  The tank will not be lined and so the modern petrol can attack the steel and cause rust. The solution would be to have the new tank lined prior to fitment.

It is always worth giving us a call to discuss the remedy.  07778 265726 and ask for Jeep.
If the tank has a previously applied liner that has failed, we remove as much of this as possible to ensure that only well bonded sealer is left. Often these are only flecks. With some old sealers it would take a remover with bifluorides to remove every trace and this is outside our service. The only advantage is that the finished tank may show some of the remaining sealer, within the final coat,  that has been completely bonded in with the new. This does not weaken the effectiveness of the coating.
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old resins | fuel tanks | Polyester | Rubber | ABS | Paint | attacked by | Ethanonl | modern pump petrol
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