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Fixing Rusted Out Gas Tank

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    #61
    I know this thread has moved on but here is the tank I mentioned earlier which originally came off my S' that was leaky at the back on the left side and was brazed all the way round, in an effort to save it.





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    Don't say can't, as anything is possible with time and effort, but, if you don't have time things get tougher and require more effort.

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      #62
      Ed - I have a pot of the POR15 stuff if you want to swap.. Can use the Caswell on my tank instead.

      Sorry to have abandoned it with you.. a lot of travelling coming up for me
      1980 GS1000G - Sold
      1978 GS1000E - Finished!
      1980 GS550E - Fixed & given to a friend
      1983 GS750ES Special - Sold
      2009 KLR 650 - Sold - gone to TX!
      1982 GS1100G - Rebuilt and finished. - Sold
      2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

      www.parasiticsanalytics.com

      TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

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        #63
        Originally posted by salty_monk View Post
        Ed - I have a pot of the POR15 stuff if you want to swap.. Can use the Caswell on my tank instead.

        Sorry to have abandoned it with you.. a lot of travelling coming up for me
        Hey Dan,

        Figured as much about the travel.

        I still have your extra tank here and will throw some acetone in it to start the liner stripping process tomorrow. The bottom edge of the tank has been welded so it will be interesting to see if it will hold the fluid. If it won't, I'm going to defer to you doing the job. I kind of like working on these tanks but have had my fill of leaking tanks.

        Did the Caswell's liner job this afternoon. Thanks for the POR-15 offer, but this tank needs the robustness of the thick epoxy sealer. Used the entire package and didn't drain out the excess. Kept the tank moving until the sealer started get thick, then positioned the tank so the excess will reinforce the front bottom, where the rust was. Tank is a fair bit heavier than before now.
        Ed

        To measure is to know.

        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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          #64
          Finished the tank today, as far as I'm going to go that is. Shot some urethane primer/sealer so it won't rust. Still needs block sanding and minor body work but it's quite close.

          Photo showing the inside of the tank looks way worse than it does in real life. The metal has a dark patena but looks like a rusted mess in the photo.

          Slammed it on ebay and will be happy to see it go. I spent WAY too much time on this project.












          Ed

          To measure is to know.

          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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            #65
            Tank is on ebay since nobody pinged me from here.

            1 hour to go and sitting at $103. I've got about $175 into it so looks like someone is going to get a bargain.

            Ed

            To measure is to know.

            Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

            Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

            Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

            KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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              #66
              Wish it was a 79 tank..thats what i am in the hunt for someday to make my red European tins for the Cooley.
              MY BIKES..1977 GS 750 B, 1978 GS 1000 C (X2)
              1978 GS 1000 E, 1979 GS 1000 S, 1973 Yamaha TX 750, 1977 Kawasaki KZ 650B1, 1975 Honda GL1000 Goldwing, 1983 CB 650SC Nighthawk, 1972 Honda CB 350K4, 74 Honda CB550

              NEVER SNEAK UP ON A SLEEPING DOG..NOT EVEN YOUR OWN.


              I would rather trust my bike to a "QUACK" that KNOWS how to fix it rather than a book worm that THINKS HE KNOWS how to fix it.

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                #67
                Sold for $126. Lost my butt.

                Lesson of the day: be careful buying used gas tanks. It it turns out to have a bunch of holes in it you're screwed.
                Ed

                To measure is to know.

                Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

                Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

                Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

                KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

                Comment


                  #68
                  Pictures are all gone in the thread

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