How to fix cracks and holes in my golf cart gas tank?

I have just noticed a nasty crack (and a small hole, maybe?) in my golf cart’s gas tank. It’s leaking and I’m really worried about the safety risks, not to mention the mess. Has anyone here successfully fixed something like this without having to buy a new tank?


I understand your concern as I had some cracks in my gas tank too. What worked for me was a two-part epoxy fix. It’s affordable and not too complicated. Just make sure the area around the crack is super clean and roughed up a bit before you apply the epoxy. It’s been holding up great so far!

Solutions that Worked for Users:

SolutionUsers Who Found SuccessApprox. Cost (USD)Approx. Time Needed (Minutes)
Two-Part Epoxy Glue1$10 – $3030 – 60
Plastic Welding with Polyethylene FillerNot quantified$20 – $5060 – 90
JB Weld’s Steel Stick and Fiberglass Patch1$15 – $4045 – 75


  • Visible crack or hole in the golf cart’s gas tank.
  • Fuel leakage from the tank.
  • Potential safety hazards due to fuel exposure.

Possible Causes:

  • Physical damage to the tank.
  • Material fatigue or wear over time.
  • Accidental punctures during maintenance or use.

Solutions that Worked:

  1. Two-Part Epoxy Glue
    • What I Did: Applied two-part epoxy glue to the cracked area after proper surface preparation.
    • Outcome: The crack was successfully sealed, and the tank no longer leaked.
    • Personal Experience: I discovered a crack on the top of my gas tank. After sanding the area and cleaning it with alcohol, I applied the epoxy. It cured well and sealed the crack effectively.
    • Estimated Cost: $10 – $30
    • Time Needed: 30 – 60 minutes
    • Steps:
      1. Identify the cracked area on the gas tank.
      2. Sand the area around the crack with coarse sandpaper to create a surface that the epoxy can adhere to.
      3. Clean the sanded area with a mild solvent like alcohol to remove any oil, grease, or dirt.
      4. Mix the two-part epoxy glue according to the manufacturer’s instructions.
      5. Apply the epoxy over the crack using a putty knife or similar tool, ensuring it fills the crack completely.
      6. Smooth out the epoxy with the knife for a neat finish.
      7. Allow it to cure as per the product instructions, usually for several hours or overnight.
    • Expert Tip: For deeper cracks, apply the epoxy in layers, allowing each layer to partially set before adding the next. This prevents the epoxy from sagging or dripping out of the crack.
  2. Plastic Welding with Polyethylene Filler
    • What I Did: Used a plastic welder kit and polyethylene filler to repair the broken filler neck.
    • Outcome: The filler neck was successfully reconstructed and functioned normally.
    • Personal Experience: Faced with a broken filler neck, I opted for plastic welding. It required careful welding, building up, sanding, and shaping, but the result was durable.
    • Estimated Cost: $20 – $50
    • Time Needed: 60 – 90 minutes
    • Steps:
      1. Prepare the broken area by cleaning and sanding.
      2. Use a plastic welder kit with polyethylene filler.
      3. Carefully weld and build up the damaged area.
      4. Sand and shape the repair for a smooth finish.
      5. Test the repair by gently pressing to ensure it’s solid.
      6. Optionally, apply a sealant over the repaired area for extra protection.
    • Expert Tip: Keep the welding iron moving to avoid burning the plastic. The key is to melt the filler and the tank material together without burning.
  3. JB Weld’s Steel Stick and Fiberglass Patch
    • What I Did: Applied JB Weld’s Steel Stick and covered it with a fiberglass patch.
    • Outcome: The hole was effectively sealed and reinforced.
    • Personal Experience: After accidentally creating a hole, I used the Steel Stick for an initial seal, then reinforced it with a fiberglass patch.
    • Estimated Cost: $15 – $40
    • Time Needed: 45 – 75 minutes
    • Steps:
      1. Rough sand the area around the hole.
      2. Apply JB Weld’s Steel Stick to the hole.
      3. Cover the area with a fiberglass cloth and resin.
      4. Allow it to cure and harden.
      5. Sand down any rough edges for a smooth finish.
    • Expert Tip: Ensure the patch covers an area larger than the hole for better strength. The resin should be applied evenly for a consistent seal.

Golf Cart Models Where This Worked:

  • Specific models were not mentioned in the threads, but these solutions are generally applicable to various golf cart models.

Safety info

  • Always work in a well-ventilated area when dealing with gas tanks and flammable materials.
  • Wear gloves and safety glasses to protect your hands and eyes during the repair process.
  • If you’re unsure about the repair, consult with a professional mechanic for advice.

Extra tips

  • For older or vintage golf carts, finding replacement tanks can be challenging, making repair a more viable option.
  • Some golf cart enthusiasts use tank liners as a preventive measure against future cracks or leaks.


Ernie loves documenting interesting facts about golf.

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