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Tank Sealer Flow Chart: The KBS 3-Step Fuel Tank Process

KBS Gold Standard Tank Sealer logo 3-Step Tank Sealing System Complete Tank Sealer Directions Plastic Tank Sealer Directions Remove an Old Tank Liner How Much Tank Sealer Do I Need? Tank Sealer Tech Data Sheet Tank Sealer Chemical Resistance Avoid Common Tank Sealer Mistakes Tank Sealer Questions and Answers Tank Sealer Instructional Videos All Application Flow Charts Order a Tank Sealer Kit

The Tank Sealer flow chart maps the KBS 3-step system for fuel tanks. Drain and remove the tank, strip any old sealer with KBS Strip, clean with KBS Klean, then prep with RustBlast for metal and fiberglass or Fusion SEP for hard plastic before pouring in Gold Standard Tank Sealer. Allow 96 hours to cure before adding fuel.

Tank Sealer Flow Chart at a Glance

3 Steps
Klean, Prep, Seal
55 to 82 F
Ideal Temp Range
96 Hours
Full Cure Before Fuel
600 F
Max Operating Temp
ALWAYS WEAR PROTECTIVE GLOVES AND SAFETY GLASSES. ALWAYS WORK IN A WELL-VENTILATED AREA. Please heed all labeled warning and caution notices on all products.
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On This Page

The Tank Sealer Flow Chart

Start at the top and follow the arrows. The yellow boxes are decisions: your answer tells you which way to go.

START WITH YOUR TANK
New Steel or AluminumRusted Steel or Corroded AluminumFiberglassHard PlasticFailing Old Sealer
Drain and Remove the Tank
Drain all fuel and remove the tank from the vehicle. Remove fittings and seal the openings with duct tape, rubber stoppers, or similar.
Is there an old sealer or liner inside the tank?
YES
Strip it out first with KBS Strip. Repeat until no old sealer remains, then continue to Step 1. See Remove an Old Tank Liner.
NO
Go straight to Step 1, KBS Klean.
Clean with KBS Klean
Mix KBS Klean 1 to 1 with hot water, pour it in, and rotate the tank so it reaches every surface. Repeat as needed, rinse until the water runs clear, and let the tank dry.
What is the tank made of?
METAL
Steel or aluminum, Step 2, RustBlast: pour in full-strength RustBlast and roll and tip the tank every 5 minutes for 30 to 60 minutes so it never dries. Drain, then rinse with water.
FIBERGLASS
Step 2, RustBlast: limit contact to about 2 minutes, since longer contact can weaken the resin. Drain and rinse with water. Fiberglass holds moisture longer, so allow extra drying time.
HARD PLASTIC
Step 2, Fusion SEP instead of RustBlast: pour into the dry tank, coat every surface for up to 10 minutes, and drain the excess right away. See the Plastic Tank Sealer Directions.
Let It Dry Thoroughly
The tank must be completely dry inside before Tank Sealer goes in. Forced air, a shop vac, a blow dryer, or a fan speeds drying. A thin white powder left by RustBlast is normal zinc phosphate and helps the seal.
Stir the sealer thoroughly, pour in the entire contents, then rotate and roll the tank for up to 30 minutes to coat every interior surface.
Important: Drain All Excess Sealer
Tip the tank and drain every bit of excess sealer for at least 30 minutes, rotating it every 5 minutes so nothing pools. Wipe sealer off threads and fuel lines before it cures.
Cure 96 Hours Before Fuel
Leave the openings open so air reaches the coating. Keep the tank out of direct sunlight and away from heat. Test with water before adding fuel.
PROJECT COMPLETE

This flow chart is a general application guideline. It does not cover every application or environmental situation. If you still have questions, contact us for technical assistance.

Download the Printable Flow Chart (PDF)

Where Does Your Tank Start?

The steps stay the same for most tanks. What changes is whether you strip first and which Step 2 prep you use.

Your Tank
What Changes
New steel or aluminum
Standard 3-step system: KBS Klean, RustBlast, Tank Sealer
Rusted steel or corroded aluminum
Standard 3-step system; repeat RustBlast for heavier rust
Fiberglass
RustBlast contact limited to about 2 minutes, extra drying time
Hard plastic
Fusion SEP replaces RustBlast; patch any holes or cracks first
Failing old sealer or liner
Strip it completely with KBS Strip, then start at Step 1
Cleaned with vinegar
Vinegar is not prep; start at Step 1

It is not necessary to remove every last bit of rust. Tank Sealer bonds directly to any remaining rust once the tank is clean, prepped, and dry.

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Timing at Each Step

Step
How Long
Before Moving On
1. KBS Klean
Soak and rotate; repeat as needed
Rinse until the water runs clear, then dry
2. RustBlast
Keep wet 30 to 60 minutes, rolling every 5 minutes (fiberglass: about 2 minutes)
Drain, rinse with water, dry completely
2. Fusion SEP (plastic)
Coat for up to 10 minutes
Drain the excess right away
3. Tank Sealer
Coat for up to 30 minutes
Drain all excess for at least 30 minutes
Cure
96 hours
Openings open, no sun or heat, test with water

Not sure which kit fits your tank? See How Much Tank Sealer Do I Need? or compare Tank Sealer Kits by tank size.

Products in This Flow Chart

KBS Klean
RustBlast
Tank Sealer
KBS Strip
Fusion SEP
Tank Sealer Kits

Frequently Asked Questions About the Tank Sealer Flow Chart

It shows the order of the KBS 3-step tank sealing system and the two decisions along the way: whether an old sealer has to be stripped out first, and what the tank is made of, which decides the Step 2 prep. For the complete procedure, see the Tank Sealer Directions and the 3-Step Tank Sealing System overview.
Drain the tank and remove it from the vehicle, clean it with KBS Klean, prep it with RustBlast (or Fusion SEP for a hard plastic tank), and let it dry completely. Then stir Gold Standard Tank Sealer, pour in the entire contents, and rotate and roll the tank for up to 30 minutes to coat every surface. Drain all excess for at least 30 minutes and let it cure 96 hours.
Allow 96 hours for Tank Sealer to reach maximum cure before adding fuel. Leave the tank openings open so air can reach the coating, keep the tank out of direct sunlight and away from heat, and test the tank with water before refilling it with fuel.
Yes. Any previous sealer or liner has to be fully removed before Step 1. Use KBS Strip, repeating until no old sealer remains. The Cycle Tank Sealer PLUS kits include a quart of KBS Strip. See Remove an Old Tank Liner Before Sealing.
Yes. Once RustBlast has kept every interior surface wet for 30 to 60 minutes, drain it and rinse the tank with water, then let it dry completely. Skipping the rinse leaves too much zinc phosphate on the surface, and rinsing too many times removes all of it.
Fiberglass uses the same three steps, but RustBlast contact is limited to about 2 minutes because longer contact can weaken the resin. Fiberglass also holds moisture longer, so allow extra drying time before sealing. KBS recommends avoiding alcohol-blended fuels in fiberglass tanks even after sealing.
Yes, if it is a hard plastic tank. Tank Sealer alone will not bond to plastic, so Fusion SEP replaces RustBlast in Step 2. The Plastic Tank Sealer Kit includes KBS Klean, Fusion SEP, and Tank Sealer. Follow the Plastic Tank Sealer Directions.
Apply Tank Sealer between 55 and 82 degrees F (13 to 28 degrees C) in moderate to dry conditions. Tank Sealer is a moisture-cured urethane, so avoid rain and high humidity, and never use direct sunlight or a heat source to speed up curing.

Still have questions about sealing your tank? Our technical team is ready to help.

More Tank Sealer questions and answers: Tank Sealer Questions

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Instructional & How-To Videos

Sealing a Motorcycle Gas Tank with the KBS Cycle Tank Sealer Kit
Simple Steps to Seal a Gas Tank with the KBS Tank Sealer System

Watch more tank sealing videos on the KBS Instructional Videos page.

Shop Tank Sealer Kits: All 3 Steps in One Box
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