What is the correct way to repair a glass tank so it will last? I'm in the process of spitting the seams (where the bottom joins the top) so I can grind the inside before I line it with a light weight cloth chop strand and vinyl ester. All advice happily accepted. And no, it's not a Norton tank. Graeme[/quote
You will need novalac vinyl ester resin, which is denoted for use with ethanol in manufacturers chemical resistance data sheets. When the tank has been sectioned, the interior surfaces should then be blast cleaned to remove all traces of oxidised fuel, to ensure a good secondary bond.
After the interior surfaces have been scoured with acetone, and have been left a couple of days to ensure they are completely dry, you can apply a chemical resistance layer, using synthetic veil (or tissue) and the novalac ve resin. Two layers of veil should be sufficient, but these must be laminated perfectly with no voids or air bubbles present at all.
Finally the 2 parts of the tank must be bonded back together using a bonding paste made using the novalac ve, and something like aerosil silica thickening agent. Before the bonding paste has fully hardened, introduce a small quantity of novalac ve into the tank, and ensure that this runs all along the bonded seams, so that any pinholes or defects can be sealed.
If there is any possibility of post curing at an elevated temperature, then this is always a good idea and will increase the final chemical resistance levels of any high cross link resin.
Not a great idea to use any product which does not have proper chemical resistance data provided by the manufacturer, and in many cases while some "sealing" resins may be quite able to resist the ethanol, they are very brittle and not suitable for use inside GRP fuel tanks, which vibrate and cause brittle materials to crack and fall off in many cases.