How to Repair a Hole in an Air Compressor Tank in 5 Steps!

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If you’re reading this article, you must wonder how to repair a hole in an air compressor tank. Many of us have faced situations where air compressor won’t hold air. An air compressor is a flexible instrument that may come in handy in a number of scenarios. If you have an air compressor at home, you can accomplish a number of tasks yourself. This is excellent news for home improvement projects. However, the air compressor may fail with time. The most typical concern is leakage during operation. Another typical leakage scenario is air compressor leaking from the bottom. That might happen because air compressor tank has pinhole leak. A compressor that won’t charge or hold pressure is annoying at best.

If this occurs, follow a troubleshooting guide to rule out other possibilities such as tank moisture or malfunctioning equipment, before determining you have an air tank leak. The bulk of leaks are caused by poor or misaligned fittings. If a leak is identified in the tank that is not on a seam or welded connection, the tank has been compromised and should be replaced rather than mended. To know in-depth how to fix air compressor tank leak, keep reading.

How to Repair a Hole in an Air Compressor Tank

Required Tools

Ensure you have all the essential tools before you begin any air compressor tank repair. To fix a tank leak, you’ll need a wrench, Teflon tape, soapy water, a brazing torch, a brazing rod, and an angle grinder. These goods are typically found in the residences of folks who prefer DIY projects. If you are missing any of these tools, go get them so you can start to work.

What Should be The State of The Air Compressor Before Restoring It?

  • Check if the air compressor regulator leaking. As the air compressor is engaged, moisture builds in the tank. If this moisture is not removed after use, it may encourage interior oxidation and weakening, making whatever welds you make unsustainable.
  • Oxidation shows that the air compressor was not maintained appropriately. Certain welding processes, such as KTIG and TIG, should not be applied on oxidized or dirty metal surfaces. Dents in the tank may also cause inner fractures that may be weakened by welding.
  • The look of spilling oil or gasoline implies that the air compressor has seen better days. It is conceivable that welding the device together will be dangerous. Welding flames have the power to ignite gasoline and oil, resulting in a fire. Welding should never be undertaken on filthy surfaces with oil or fuel residue.

Step-By-Step Process On How To Repair An Air Compressor Tank

Step 1

Take away all of the hoses and tools from the system. Turn on the compressor and leave it to completely charge. Spray soapy water over fittings, including the emergency release valve and tank-bleed fitting on the tank’s bottom, using a spray bottle. Look for bubbles, which indicate that air is leaving the system. Using a wrench, tighten any fittings that are leaking air. If the bubbling remains, move to the next step to prevent air compressor losing air.

Step 2

Pull the ring on the emergency release valve to relieve pressure in the tank. Using a wrench, remove any fittings that have indicated symptoms of leaking. Turn them counterclockwise to loosen and remove them. Replace any fittings that look to be worn or damaged. Wrap Teflon tape over the threads before inserting and tightening the new fitting clockwise. Recharge the compressor and spray it with soapy water to put it through another test.

Step 3

Spray the tank with the soap solution if the leak continues and is not caused by fittings. Look for bubbling at welded-on brackets and seams on the tank. Mark any locations that appear to be leaking with chalk.

Step 4

Turn off the electricity to the compressor or unhook the power line. As previously suggested, apply the release valve to lessen tank pressure. Grind off the elevated metal at the weld or seam with an angle grinder to reveal the hole or fracture. Grind the surface until it is level and smooth with the tank’s surface.

Step 5

Melt the metal together using a brazing torch. Light the torch with welding lighter after turning on the gas. Turn on the oxygen and heat the area to be repaired until the flame is brilliant blue. Rebuild the welded piece and seal the tank using a brass brazing rod. While the metal melts, keep the torch on it, covering the damaged area. Apply pressure on the hot rod until it melts and pools. Allow the repair to cool completely before turning the compressor back on and allowing it to recharge.

Another section of the compressor tank where leaks are accumulating is around the hose connections and shut-off valve. A tiny leak here may considerably fall in total system pressure, causing your air tools to function inefficiently.

If you do the previously mentioned air compressor tank leak inspection and find that the fittings are the source of your air leaks, you may correct a leak between the tank and the hose by following these steps:

  • Tighten any slack hose joints and fittings (use soapy water or, even better, an ultrasonic detector)
  • If required, trim the hose immediately above the tank fitting and reattach the compression ring.
  • To release pressure, tighten and twist the pressure valve nut clockwise.
  • Wrap PTFE tape over the threads of the air compressor tanks replacement valve fitting, tighten the nut with a wrench on the compression ring and check whether the problem persists with soapy water or an ultrasonic detector
  • If the problem persists, replace the fitting in the same manner until there is no evidence of a leak.

Additional Tips on How to Repair a Hole in An Air Compressor Tank

  • Under no circumstances may a highly damaged or corroded tank be repaired, welded, or brazed. The threat of an explosion is too severe to do anything other than replacing a poor weld or seam. Large amounts of sand in the pressure tank often suggest a clogged intake screen. This should be adjusted as soon as possible to prevent harm to the pump
  • If a bladder tank develops a progressive leak after rising pressure, the pressure should be checked daily for at least two weeks. Tanks with a leaky or ruptured bladder should be replaced as soon as possible to prevent causing harm to the good pump.

Let’s Watch a Video Tutorial!


If you thoroughly follow the suggestions, there will be no leakage. To avoid issues, only apply heat to a particular spot. For safety reasons, never leave any air in the tank. Use protective gloves and glasses as well for your own safety. You started reading this with the query, “how to repair a hole in an air compressor tank?”. Hopefully, now you’re equipped with the essentials of how to stop air compressor leaks.

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