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Does the 2009 Gas Tank fit on a 2010 ?

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Old 05-03-2011, 08:51 AM   #1
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Does the 2009 Gas Tank fit on a 2010 ?

I need to replace my gas tank and at 1100$ at the dealer I'm looking for a used one.

I found a 2009 in a scrap yard, the guy tells me it's exactly the same for 2005-2010, can I trust him ? Another yard who had a 2006 says that they fit up to 2009 but that it's different on a 2010.
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Old 05-03-2011, 09:08 AM   #3
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I would really doubt they are different.
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Old 05-03-2011, 04:22 PM   #5
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its plastic and all 2005-2010 should be the same
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Old 05-03-2011, 06:14 PM   #6
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I have another question. Is it Polyethylene plastic ?

Maybe it's time I tell the story if I want answers. I needed to drill holes in my bed, I f... up when measuring to clear the gas tank and I made a small hole in it. The dealer wants 1100$ for a new one + 400$ in labor + tax.

I can find a used one for about 200$ but with installation and tax it's still gonna cost me 700$.

Some people have suggested I put some J-B Weld on a bolt, plug the hole with it and then generously apply more J-B Weld on top of it. It would probably work if the epoxy bonds to the tank but if it's polyethylene I doubt that anything will.
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Old 05-03-2011, 06:21 PM   #7
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Quote:
Originally Posted by EricGagne View Post
I have another question. Is it Polyethylene plastic ?

Maybe it's time I tell the story if I want answers. I needed to drill holes in my bed, I f... up when measuring to clear the gas tank and I made a small hole in it. The dealer wants 1100$ for a new one + 400$ in labor + tax.

I can find a used one for about 200$ but with installation and tax it's still gonna cost me 700$.

Some people have suggested I put some J-B Weld on a bolt, plug the hole with it and then generously apply more J-B Weld on top of it. It would probably work if the epoxy bonds to the tank but if it's polyethylene I doubt that anything will.
i would go this rout personally. or can you tap threads into it and just screw a bolt in and jb weld the out side just incase?
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Old 05-04-2011, 07:12 AM   #8
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I don't think silicon will hold on HDPE, nothing can stick to this sh...

Maybe it would work for a vehicle that stays on roads but after thinking about it a lot, I came to the conclusion that nothing will safely stay there when I go overlanding and drive thousands of miles on washboards.

The dealer found a used tank for me. That 300$ instead of 1115$ for a new one. It's still gonna cost me 800$ with labor and car rental but that's better than 2000$ and I won't have to worry about blowing up if somebody smokes near my truck.

P.S: I hope people will read this and learn from my mistakes. If you ever need to drill in the front end of your bed, don't be as stupid as I was. Go to your hardware store, buy a drill bit stopper and make sure you can't go more than 1/4". Trust me, this composite sh.. is hard as hell, you're gonna have to push hard on your drill to go through and without a stopper you WILL drill a hole in your tank without even feeling it.
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Old 05-11-2011, 01:15 PM   #10
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I think I found the right stuff. It's made by 3M and they call it "Scotch-Weld Structural Plastic Adhesive". It's designed specially to bond with polyethylene and polypropylene.

It's a 2 parts Epoxy with a 10:1 mix ratio. It comes in a weird looking tube and a special distributor that mixes it automatically. The distributor is of course reusable so you only buy it once.

Here's how I'm gonna do this.

1: Clean the surface with isopropyl alcohol.
2: Sand the surface
3: Clear again with alcohol
4: Cover the area with the epoxy
5: Pass a bolt through a piece of fiberglass mat
6: Apply the mat on the epoxy with the bolt in the hole (passing the bolt through will make sure the fiberglass stays flat on my tank
7: Make sure the mat is pressed in the epoxy everywhere
8: Have a beer and allow it to cure for about an hour
9: Add some epoxy over and around the bolt
10: Have a beer and allow it to cure for about an hour
11: Generously spread epoxy on top of the fiberglass
12: Put a wider piece of fiberglass mat on top of the bolt and first piece of fiberglass
13: Press firmly in the epoxy to insure full contact everywhere
14: Have a beer and let it cure for about an hour
15: Spread equally whatever is left of the epoxy on top of all this and let cure for at least 12 hours before using the truck.

I'm a step 8 now. The stuff seemed to bond well with the plastic of the tank when I started. It smells like sh.. but it seems to work.

Will let you know how the next steps go.
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Old 05-11-2011, 01:19 PM   #11
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Buy the fuel tank, and install it yourself. Get a buddy. Take the bed off, which is very easy. 6 bolts, and unplug the lights, and fuel filler, and it lifts off. Then, just swap the tank.
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Old 05-11-2011, 01:43 PM   #12
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That's what I'm gonna have to do if my fix doesn't work but I'm confident it will. I'm not the first guy who fixes a hole in a fuel tank with a patch of fiberglass and epoxy, I just needed to find something that bonds to HDPE/PE/PP (whatever our tanks are made of).

Forgot to put links to the stuff.

Epoxy: http://www.shop3m.com/62278304308.html
Applicator: http://www.shop3m.com/62917099301.html
10:1 Plunger (sold separately): http://www.shop3m.com/62917099103.html
Nozzles: http://www.shop3m.com/62974299356.html

3M only sells in large quantiites but it's easy to find online retailers to buy in eaches. For Canada I found everything I needed at National Hardware Sales. First dealing with them but very satisfied.
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