Cooley tank dent removal pics

[chuck hahn]

Was first time trying such a thing. This dent was there when I got the bike and was about the size of a tennis ball..nice easy bowl shaped dent.

Took a rod and bent it, welded on a thick washer and filledthe center of the washer with weld for the working pad area.

Next I shaped it with the grinder to be round topped and took some off the back side so it wouldn't make UP DINGS from the inside of the tank. Made a mark with a marker and inserted it in the tank.

Felt as I tapped the knob on the tank and when I had it where it needed, then some leverage and lifted the dent. Dent was just above the white right where the blue starts..just above the scrape in the white paint.

Heres the tool I made...





Heres the repaired area..ever so slightly able to see it if you glare then sun off the paint. Not bad for the first try...and I had to do it on the Cooley no less!!!

[gustovh]

Nice job, they call those slaphammers. Normaly they have a pad on the end on the outside to give a pop with a hammer....thus slaphammer. I have a dent tward the bottom top on my Rebel's tank that I havent been able to figure a way to shape the tool to get to it...go figure.
V

[Vmass]

Nice work Chuck. You seem to keep that Cooley out of site.....eh!!

[chuck hahn]

Well Rich, between you and Joe Whelan, I gotta keep her hidden!! Rascals will simply roll her away in the night!!! OL.

[jwhelan65]

Ok now I will buy it..

[chuck hahn]

I am keeping a good eye on YOUR ( HA HA ) BIKE Joe!!! But with the tank pretty well taken care of now, you know I will have to have more...right??? LOL.

Started her today too and cleaned the wire connectors from the stator and checked the charging..basic exams were due. Passed till the next time. the next

[sedelen]

Chuck,
Wished you had a before pic, as far as the after pic, I can't see any imperfections in the metal.
Looks like you took that dent wizard video to heart.
Congratulations!