Caswell Fuel Tank Sealer Kit
Caswell Fuel Tank Sealer
Owner Report by Scott S.
| Owner Comments (Below)
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Maintenance and Repair Articles
One of the more common problems encountered with seasonal equipment is
the prevention of rust and corrosion activity during the off-season.
the Northeast U.S., we routinely store our lawnmowers, boats and motorcycles for
extended months during the winter.
While we would all prefer to have the use
of a heated and humidity-controlled storage facility, the more common
scenario for most of us is an unheated garage or outbuilding.
even a properly prepped bike will be susceptible to some corrosion and rust
under these conditions, and my Triumph Legend apparently developed some rust
in the fuel tank while under the care of a previous owner.
Rust and corrosion on the body of a bike is usually noticed quickly, and can
be addressed before it gets too far out of hand. Rust inside the fuel tank,
however, may go undetected until it reaches an advanced state.
(?), the Triumph Classic Triples are very sensitive to dirty fuel, and upon
disassembling my Keihin carburetors to investigate a bit of rough running, I
discovered a generous dose of rusty sediment in my float bowls. Time for a
Since I had no previous experience sealing a fuel tank, I did what any
self-respecting novice would do and turned to the internet for some basic research.
I discovered several fuel tank sealing kits on the market
but I selected the Caswell
product because it is made here in New York and I found no negative reviews
about it. Ordering directly from the manufacturer, I had the kit in my
hands in just a few days.
About the Caswell Fuel Tank Sealer Product
The Caswell product is a "phenol novolac epoxy", according to the
company. It's claimed to be chemically resistant and "able to
withstand permanent immersion of many harsh solvents, fuels and oils".
Caswell also says that the epoxy used in the kit "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 rusty surface".
Caswell also lists many other uses for the epoxy; it can be
used as a battery component coating; a high-strength adhesive; a potting
compound to encase electronics; for repairing leaks in concrete; as a
general bonding solution and to make molds or repairs.
The Caswell Fuel Tank Sealer Kit
Upon opening the box, I found two steel cans which were tightly
sealed with clips and a sheet of instructions. These were divided into 3
categories: Preparation, Mixing and Application. Each category has
several steps, and the instructions are clear and easy to understand.
Here is a quick summary of what is actually involved in sealing a tank:
Step 1: Remove the tank, and wrap it with a protective cover. The
plastic shrink wrap (Amazon.com)
followed by aluminum foil and then one
additional layer of shrink wrap.
I improved on this a bit, and used a roll of
shrink wrap plastic similar to what shippers use to wrap large pallets. This
is available at most discount stores, and it adheres very tightly. I used
the "mummy" wrapping technique, without using aluminum foil.
Step 2: Flush with acetone or lacquer thinner. I used a funnel and
carefully poured in a quart of acetone, and then plugged the filler hole
with a big rubber stopper wrapped with more shrink wrap plastic.
then taped down tight with Gorilla Tape (Amazon.com).
The printed directions call for
sealing the filler hole with more Glad Wrap and a rubber band, but my
Triumph tank has a sunken filler tube, so there was nothing to hold the
To plug the petcock hole, I simply used a piece of rubber
underneath the petcock spacer block, and a couple of oversize nuts to run
the bolts through to take up their extra length without the petcock
included. The directions suggest Silly Putty
for this role, but since I had
to use the petcock as the drain because of the sunken filler neck, my method
was faster and cleaner.
The directions also called for adding some sheetrock
screws to be agitated with the solvent, but my filler design would have made
their removal questionable, so I skipped this step.
Step 3: After dumping out the acetone, add dish detergent and hot water
(Dawn brand is recommended)
and then flush once again so no residue is left to interfere with the
adhesion of the epoxy.
Then let the tank dry thoroughly. I left mine in the
hot sun all day, although if you are on a tighter schedule, you can set up
an air hose to circulate air through the tank, and thus reduce the time
needed to achieve a dry tank.
Step 4: Now it's time to mix up the epoxy and pour it in.
A cheap funnel and an empty plastic container can be used for this; I used a cottage
cheese container and a plastic spoon to stir the mix.
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Applying the Caswell Fuel Tank Sealer
While the directions state that a five-gallon tank will only require half of the
kit, I found that I wasnít getting enough coverage even after turning the
tank for 15 minutes, so I mixed up the other half and poured it in.
After another 15 minutes of turning the tank every which way to spread
the honey-like product inside (I recommend a chair for this, as you can rest
it on your lap), I removed the petcock plug and let the excess drain into
the plastic container. Then I left the tank in a warm garage overnight and finally
back into the hot sun the following day to finish.
Once it dried, it became a smooth, glass-like coating, completely encasing
the surface rust underneath. The shape of my tank caused the sealer to pool
up in thicker amounts along the outside seam areas, but I donít anticipate
that this extra thickness will cause any problems, as this product is also
used to "pot" or contain electronic circuits, where the components are placed in a
receptacle and then filled over.
While slightly time-consuming due to the drying times required at the end of
the rinse stage and again once the epoxy is applied, overall this was a very
Due to my local climate, I would not hesitate to use this
product even on a brand new steel tank as a preventative measure, and I
would certainly use it again for a rusted tank. Kudos to Caswell for
developing such an easy-to-use kit!
Review: Caswell Fuel Tank Sealer
||Suggested Retail Price:
$39.99 per pint (claimed to seal motorcycle fuel tanks up to 10 Gal.)
||Made In: U.S.A.
|Review Date: May
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From "S.C." (6/10): "I used this product last winter on
my 77 Guzzi LeMans tank; in the past I have used Por and Kream Coat with
I like the fact that you don't have to get rid of the rust
with the Caswell, so no acid cleaning which is a nice step not to do.
I used the sheet rock screws, to get them out I used a shop
magnet on a flexible neck to remove them. Also, before cleaning used a
length of chain to loosen up the rust then stuck a shop vac to suck it out.
I was able to use half a can and from what I can tell I got good coverage.
I am going to use the rest on a 74 Kawasaki F7 175 I just
picked up. I'm happy with the Caswell tank sealer and would use it