The problem with using a bolt, is that you cannot get a nut on the inside, without removing the tank, maybe not even then.

I would suggest something like a large toggle bolt, with a washer and a rubber washer or maybe some kind of gasoline-proof sealant on the outside.

Toggle bolt sizing https://www.fastenermart.com/files/t...imensions.html

A discussion on gasoline-proof sealant https://www.rcuniverse.com/forum/gas...f-sealant.html

 

A dime! Yikes! I doubt Bondo would work for that.

You realize this actually isn't a bad idea. Not literally, but I was thinking he could make a patch to cover the hole and gluing it with JB Weld for gas tanks.

 

Actually plastic welding would be possible. Tank out of car, stripped of parts and drained. Let dry.... Fill with water with the hole at the top and weld in the patch.

We used to do this with bike tanks back in the day....

 

I think I might give your toggle bolt idea a try! Thanks

 

Just buy a tank and stop over thinking the wheel.

 

So you want him to just park the car for another month while waiting for a new fuel tank to ship to Europe?

I do recommend buying a new tank, but this might work for a temporary fix.

 

I'm guessing the hole is on the bottom, flat part of the tank ? If so, you can most likely do a temp fix on a hole in that part of the tank. If it's on any part of the curvature of the edge, almost impossible to get a "plug" fix to work there.
I've done some temporary tank fixes over the years at accident scenes. We used to carry that patch putty on the fire truck. That stuff hardly ever worked. I've even used a piece of wood, smeared with that putty and jammed it in the leaking area.

One question though. The HHR is a low to the ground car. How in the heck did the gas thief get a drill under there to make the hole ? And what did he drain the gas into ? Can't even get a 1 gallon can under there.

 

I guess the product made for just this case is out of the question. There are at least 3 brand name product on this Amazon page.