How to Use a Welder to Fill a Hole in a Propane Tank

If you own a propane tank that has been punctured, you can repair the site of the hole by welding it closed. However, it is strongly recommended that any punctured propane tank be replaced rather than repaired. If you choose to use the propane tank for a purpose other than storing propane, you can safely and securely fix a puncture with a common arc welder. Most propane refill facilities will not fill a tank that has any signs of repair because of safety and regulatory concerns.

Angle grinder
Arc welder and rods
Welding face mask, gloves, apron

Instructions

- 1
  Open the valve on the tank fully to ensure any remaining propane that has not escaped through the punctured hole has evacuated the cylinder.
- 2
  Clean the site of the puncture of paint, dirt, grease or other contamination using an angle grinder. Clean 1 inch of metal around the perimeter of the puncture.
- 3
  Attach the black ground cable from your arc welder to a bare metal surface on the propane tank. Turn on the arc welding machine. Put on your protective face mask, gloves and apron.
- 4
  Fasten a welding rod into the electrode holder. Orient the tank so that the site of the puncture is facing upward.
- 5
  Strike an arc with the tip of the welding rod around the hole, then work the tip in a circular motion around the site of the puncture, allowing the weld puddle to fill the hole in the tank.
- 6
  Allow for the weld site to cool before touching, sanding or painting as you like.

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