How to Weld an Oil Pan
An oil pan leak is not the end of your vehicle's useful life. Oil pans can be welded if they crack or develop holes. Welding oil pans poses fire, explosion and inhalation risks to the welder and anyone in the repair shop. It is vital to remove all oil and volatile gas residue from the oil pan before welding. Oil pans should never be welded while still attached to the vehicle.
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Things You'll Need
- Fully-equipped welding and auto repair shop
- Approved flammable liquids container
- Warm, soapy water
- Solvent
- Clean rags
- Wrap-around eye protection
- Wire wheel on right angle grinder
- Welding helmet, gloves and full leathers
- Sheet metal
- Welder
- Leak test equipment
- Motor oil
Instructions
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1
Remove the oil pan plug and drain all of the oil from the vehicle into an approved container for use with flammable liquids. According to the National Institute for Occupational Safety and Health Fatality Assessment and Control Evaluation program at CDC.gov, "While used vehicle oil typically has a low vapor pressure, and is not perceived to be explosive, it can contain ... some amount of gasoline or other volatile compounds, which will vaporize in the container where the used oil is stored, creating an explosion hazard."
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2
Remove the oil pan according to the instructions for your vehicle's make, model and year.
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3
Rinse the oil pan with warm soapy water and drain into an approved container. Repeat until no oil residue is visible in the rinse water. Allow the oil pan to dry completely.
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4
Wipe the entire oil pan inside and out with solvent. Dry the oil pan completely with clean rags. Return the solvent to its storage locker, well away from your welding work area. Remove all rags and any other flammables or spark sources from the work area.
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5
Don wrap-around eye protection. Attach a wire wheel to a right-angle grinder and clean the area to be welded.
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Don welding helmet, gloves and full leathers.
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Weld a sheet metal patch over any large cracks or holes. Chamfer short cracks and weld from 1 inch before the crack starts to 1 inch after it ends.
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8
Test the oil pan for leaks. Reinstall according to the manufacturer's instructions for your vehicle make, model and year.
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Tips & Warnings
While it might be tempting to weld an oil pan while it is still on the vehicle, the chance of starting an engine fire is not worth the time it might save.
According to the NIOSH/FACE program, "Specific regulations for welding or cutting containers state that no welding or cutting or other hot work shall be performed on used drums, barrels, tanks or other containers until they have been cleaned so thoroughly as to make absolutely certain that there are no flammable materials present. The containers must be vented, and purging with inert gas is recommended."
