19/12/2022
Many classic car enthusiasts and owners of older vehicles will be familiar with the common problem of a deteriorating fuel tank. Often, these tanks are no longer in production, making replacement an impossible task. While professional welding can offer a robust repair, there's another highly effective solution for extending the life of your ageing fuel tank: internal tank lining. Specifically, products like the Flowliner Armour Coat Ethanol Proof Tank Liner offer a modern approach to preserving these vital components.
Why Bother with an Internal Tank Coating?
The primary reason for applying an internal tank coating is to combat the damaging effects of modern fuels. The unfortunate reality is that the introduction of ethanol into petrol has caused significant problems for older fuel systems. Ethanol is hygroscopic, meaning it attracts and absorbs water. This absorbed water can lead to corrosion and rust formation within the metal fuel tank. Over time, this rust can break free, clogging fuel filters, carburettors, and injectors, leading to poor running or even complete failure. An internal coating acts as a barrier, sealing small leaks and, crucially, protecting the metal structure from the corrosive effects of both water and ethanol.
The Challenge of Ethanol in Fuels
For decades, fuel tank coatings have been a go-to solution for tank repair. However, many older formulations simply cannot withstand the chemical composition of modern fuels, particularly those containing ethanol. They can degrade, peel, and eventually fail, exacerbating the very problems they were intended to solve. This is where specialised products like the Flowliner Armour Coat come into their own. It has been specifically developed to be resistant to alcohol products, including ethanol, ensuring a long-lasting and effective seal.
Flowliner Armour Coat: A Modern Solution
Flowliner Armour Coat is a two-pack, solvent-free epoxy fuel tank coating. Its purpose is to prolong the life of your ageing fuel tank by creating a tough, impermeable inner lining. This lining effectively seals minor leaks that might otherwise render a tank unusable. Furthermore, it provides a critical protective layer against the rusting that occurs due to the hygroscopic nature of modern fuels. Unlike many other coatings, Flowliner Armour Coat is claimed to be 100% Ethanol proof, making it an ideal choice for vehicles that will run on modern E5 or even E10 fuels.
Suitability for Different Tank Materials
While primarily designed for metal tanks, Flowliner Armour Coat is also versatile enough to be used on other materials. It is suitable for sealing fibreglass petrol tanks, protecting them from ethanol attack. Additionally, it can be used to eliminate tank distortion in nylon or plastic tanks. This broad applicability makes it a valuable product for a wide range of classic and modern vehicles.
The Application Process: A Step-by-Step Guide
Applying an internal tank coating requires careful preparation to ensure a durable and effective result. While professional application is an option, particularly for those seeking peace of mind, it can be a manageable DIY task for the mechanically inclined. Here’s a general overview of the process:
1. Tank Preparation: The Crucial First Step
This is arguably the most important stage. The tank must be completely clean and free from any old fuel, debris, rust, or contaminants. This typically involves:
- Draining: Thoroughly drain all old fuel.
- Cleaning: Use a suitable tank cleaner or degreaser to remove any residue. For heavily rusted tanks, the use of a rust remover, such as Flowliner Bio Rust, is highly recommended prior to lining. This will effectively remove all internal rust.
- Flushing: Rinse the tank thoroughly with clean water. Ensure all cleaning agents and water are completely removed.
- Drying: The tank must be bone dry before applying the coating. This can be achieved by leaving it to air dry in a warm, well-ventilated area, or by using compressed air to blow out any moisture. Any remaining moisture will compromise the adhesion and effectiveness of the coating.
2. Mixing the Coating
Flowliner Armour Coat is a two-pack system. It's essential to mix the two components in the correct proportions as specified by the manufacturer. Failure to do so can result in the coating not curing properly. Mix thoroughly, ensuring no unmixed streaks remain. This mixing process is critical for achieving the stated ethanol resistance and durability.
3. Applying the Coating
Once mixed, the coating needs to be applied to the entire internal surface of the tank. The method of application will depend on the product, but typically involves sloshing the mixed coating around inside the tank. Ensure every internal surface, including corners and crevices, is coated. Allow the coating to flow and spread evenly. You may need to rotate the tank to ensure complete coverage.
4. Curing
After application, the tank needs to be left to cure. The curing time will vary depending on the product and ambient temperature. It's vital to allow the coating to cure fully to achieve its maximum hardness and chemical resistance. Refer to the manufacturer's instructions for specific curing times. During this period, the tank should be kept in a clean, dust-free environment.
Choosing the Right Kit
Flowliner offers various kit sizes to suit different tank capacities. For instance, a 625-gram kit is typically sufficient for most tanks up to 25 litres. It's important to select a kit that matches your tank's volume to ensure you have enough product for complete coverage without excessive waste.
Important Considerations and Limitations
When considering internal tank lining, there are a few points to keep in mind:
- Postal Restrictions: Be aware that some products, like Flowliner, may have postal restrictions. For example, they might only be deliverable to mainland UK addresses due to the nature of the chemicals involved. Always check delivery information before ordering.
- Plastic Tanks: While Flowliner can be used on plastic tanks, the process can be trickier than with steel. Surface preparation and adhesion might require specific attention. If you're unsure, professional application is advisable.
- Professional vs. DIY: While a DIY approach can save money, the success of the repair hinges on meticulous preparation and application. If the tank is particularly valuable or you lack confidence, professional repair services are available.
Flowliner Armour Coat vs. Other Solutions
When comparing solutions, it's important to consider the long-term viability. Traditional methods like welding can be effective but are labour-intensive and may not always be feasible for corroded tanks. Other internal coatings might offer a temporary fix but fail when exposed to ethanol. Flowliner Armour Coat distinguishes itself through its specific formulation designed for ethanol resistance and longevity.
| Method | Pros | Cons | Suitability for Ethanol Fuels |
|---|---|---|---|
| Replacement with New Tank | Guaranteed to be in perfect condition | Often unavailable for older vehicles, expensive | High (if specified for modern fuels) |
| Professional Welding Repair | Can restore structural integrity, durable | Requires skilled labour, cost, may not be possible for severe corrosion | Depends on welds and original tank material |
| Internal Tank Lining (e.g., Flowliner) | Cost-effective, seals leaks, prevents rust, can be DIY | Requires meticulous preparation, potential for user error, coating can fail if not ethanol-proof | High (if specifically ethanol-proof) |
| Internal Tank Lining (Standard) | Cost-effective, seals leaks | Can fail prematurely with ethanol, requires preparation | Low to Medium |
Frequently Asked Questions
Q1: Can I use Flowliner Armour Coat on a diesel tank?
Flowliner Armour Coat is specifically formulated for petrol tanks and resistance to ethanol. While it may offer some protection for diesel, it is not its intended use, and compatibility with diesel additives is not guaranteed. Always check manufacturer specifications for specific applications.
Q2: How long does Flowliner Armour Coat last?
When applied correctly to a properly prepared tank, Flowliner Armour Coat is designed for long-term durability and resistance to modern fuels, including ethanol. The lifespan will depend on factors such as fuel quality, storage conditions, and driving habits, but it is intended to significantly extend the usable life of the fuel tank.
Q3: What happens if I don't prepare the tank properly?
Improper preparation, such as failing to remove all rust or moisture, will lead to poor adhesion of the coating. This can result in the coating peeling or blistering, failing to seal leaks effectively, and ultimately compromising the integrity of the repair. It may even lead to the coating breaking down and contaminating the fuel system.
Q4: Is it safe to use ethanol fuels with a lined tank?
Yes, provided the lining product is specifically designed to be ethanol-proof, such as Flowliner Armour Coat. Using ethanol fuels with a standard, non-ethanol-proof lining can cause the lining to degrade rapidly, leading to the issues mentioned previously.
Conclusion
For owners of vehicles with ageing or problematic fuel tanks, particularly those facing the challenges posed by modern ethanol-laced fuels, internal tank lining presents a viable and often necessary solution. Products like Flowliner Armour Coat offer a specialised, ethanol-proof coating designed to seal leaks and protect against corrosion, thereby preserving these critical components when replacements are unobtainable. With careful preparation and application, an internal tank lining can provide years of reliable service, keeping your classic or older vehicle on the road.
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