Is this tank salvageable?

[ironfoot]

Hello all,

Long story, shortened; I have a mutt skunk that the po put a later model tank on. He used the original petcock which was 44 mm and modified the petcock bolt holes (widened) to fit a 50 mm petcock tank base, and widened the fuel tank hole to fit the screened fuel tap of the 44 mm petcock, slapped that baby in there and covered the whole works bolts, petcock base and tank with JB Weld or Bondo to stop it from leaking. This was not visible with the tank on and I only discovered it, of course, after going after the petcock to rebuild. The petcock is a total loss as I had to cut it off due to not being able to remove the bolts (the heads were buried in the bondo mess). The tank fuel tap hole is now widened beyond its stock position and I think it will leak with the proper 50 mm petcock installed. Need your opinions, options. Thanks.

[Dave8338]

HOLY-CRAP: Alrighty then ...let me see if I have this correctly. PO swapped out the petcock for another and now the "other is leaking" and beyond repair???

This being the case, I would first...source another tank.! .!! .!!

IF...you want to push this issue through, (I would... and there are those on here that would flame me for it) start by:

1) remove said wrong petcock.
2) purchase the correct petcock from http://www.bikebandit.com/?WT.mc_id=...03&PID=3867892
OR http://z1enterprises.com/ (you didn't mention what bike you are working on...)
3) Weld/Braise/anything Non-Glue, the correct petcock mounting nusts in place, and make your own gasket.

Anything short of buying a new (used) tank, will leave you with leaks and PI$$ED OFF..... unless you are good with a welder. I can fix that.......................

[Steve]

... (you didn't mention what bike you are working on...) ...

Sure he did, Dave.

Hello all,

Long story, shortened; I have a mutt skunk that the po put a later model tank on. ...

In my book, that's a '78 GS1000.

.

[mighty13d]

if you can afford a correct and new petcock, buy one and the gaskets for it and slap it on there. you might be pleasantly surprised at the outcome.

[ironfoot]

HOLY-CRAP: Alrighty then ...let me see if I have this correctly. PO swapped out the petcock for another and now the "other is leaking" and beyond repair???

Actually the po replaced the tank with a 1980 tank, then tried to use the old petcock from the '78 tank; they're not the same bolt pattern. Then he tried to patch the leak from his hack job by slathering JB weld over the base of the petcock and on the tank. I had to destroy the petcock to get it off the tank.

Thanks for the offer to repair; a welder I am not.

if you can afford a correct and new petcock, buy one and the gaskets for it and slap it on there. you might be pleasantly surprised at the outcome.

I need a pleasant surprise about now. I may try that, once my positive mindset comes back around.

[Dave8338]

Sure he did, Dave.

In my book, that's a '78 GS1000.

.

You got me there, Steve.

Use the existig holes and tack a pair of nuts in place, refit the correct petcock, and go from there.

[GSexpress]

I would make a thin metal plate with the correct (original) hole and bolt patter for a new petcock. Then JB weld it to the tank. If the threads in the tank are messed up I would slip a locking coller type nut ( the ones that look like they have a washer attached to it) on the inside of the tank and JB weld it in place first by temporarily bolt ing everything in place just to position the nut. (put oil on the threads of the bolt) Once that sets up then JB weld the plate and assemble everything. This will give you a new mating surface for the new petcock and allow you to bolt it in place. The JB weld will seal the new plate to the old tank. Your petcock will seal to the new plate and the JB weld will be sandwiched inbetween.

[Nessism]

Worst case is fabricate a plate with the proper petcock spacing and have it welded to the tank. Not that big a deal, although the welding heat might destroy the paint.

[ironfoot]

Good tips all, thanks!