Fuel Tank Crack on early model j2's and RD's
 

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i'm sure some of you are aware of the crack prone tanks on certain j2/RD Elantra's.



it seem's my car has been taken to the dealer several years ago before i owned it and they had it inspected but didn't have the correct cap replaced, plus, i'm at a stalemate with hyundai consumer affairs on getting my tank replaced, so i said screw it! for 2 years..i've been driving with a crack in my gas tank that won't stay sealed no matter what i tried..3 applications of permatex epoxy..failed!2 applications of Q-Bond..Failed!..2 aplication os JB Weld original cold weld..Failed!..the dreaded P0442 light comes on to inform me my patchwork didn't cut it. :fire1: and this was on a solvent cleaned and rough sanded surface



the crack in tank is next to the fuel sending unit on the driver side..and accessing it is hard, so i took a dremel and cut the part on top of the crack and is readily accessible..i'm contemplating on draining & drying out the tank and welding it..or hope the old hose's and lines are still good and order a new tank from rockauto and have it painted with truck bed coating for added rust protection



my main question is..are anyone else aware of the same problem on their 2g elantras?

never seen nor heard of such an issue.

and I've owned a few cars from that generation

mostly affect 96 and 97 J2/RD elantra's and tibs...i bought and installed the correct gas cap but i guess it was too late..the damage was done.



may have to blow $130 on a new tank..hope i don't have to.

Surely a used gas tank from a wrecked car on CL would cost you less than an hour's wage

true..true..but i'm limited to means in terms of where i can work on my car..



if i lived in a garaged house i'd swap the tank...may have to borrow my friends driveway.



there's a few more methods i'm gonna try before replacing or welding the tank.



i'm gonna try to hammer the crack from the inside and try to flush the gap on the crack as close as i can and solder it..

You don't solder steel. Well ok you can solder steel if you are a stud with the right kind of torch, and welding would probably be easier for a non-wizard to do. Welding might work if you don't blow through the metal. If you're prepared to weld it, be prepared to replace it just in case. As long as you're already to the end of your options, why not try bolting/screwing a patch plate inside the tank, with a silicone gasket and silicone seals on both sides of the screws?

My 97 Tib had a cracked tank but I think it might have had to do with my really nasty encounter with the median.

None of this sounds easier than simply unbolting the straps under the tank.

i donno about you, but of all the fluids that can leak from a vehicle, gasoline leaks scare the f*ck out of me the most.



do it right the first time or youll regret it. try to rig a transmission leak and you might have to replace a transmission. try to rig a fuel leak...well the outcome isnt so nice.



http://images.thecarconnection.com/m...00178747_m.jpg

i have a mini butane torch and a propane torch..local mean's wise "lowes, home depot, ace hardware"..is there any soldering rods useful for patching steel tanks?