Fuel tank refurbishment

The Mini’s fuel tanks were a bit rusty on the inside, a situation not all that unexpected on a 50 year old car. Fortunately, there’s a brilliant and fun way of restoring them; electrolysis!

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There’s an in-depth guide to electrolytic rust removal on Andy Westcott’s page, which was enormously helpful. Brian used a length of steel reinforcing rod as the sacrificial anode, and a high current 5 volt power supply (a computer power supply is perfect).

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After about a week of electrolysis the fuel tanks were looking much tidier inside.

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A good slosh around with POR15 fuel tank repair kit, and they’re better than new.

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Now for the outsides. What looked like slightly faded black paint turned out to be thinly applied underseal, hiding a very even coating of surface rust. *Sigh*.

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The sandblaster made short work of the rust…

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A coat of etch primer, then epoxy enamel, and we have two gorgeous fuel tanks.

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