Follow up to my last couple of threads

[kparkfan]

Ok here is what I found out about what is causing my leaks around my petcock. upon further investigation I have found that there are some small grooves in the metal where there once was paint. I went ahead and used some non hardening sealant to see if it would help and it now only gets a little damp but no where as bad as it was. Still not safe to me.

I was talking to another motorcyclist who said something about maybe having it brazed. I'm know body guy so have no clue really as to what he is talking about. Is there anything you guys would suggest doing to cure my problem with the grooves. I plan on having the bike painted over the winter just need to save up for that and find someone who I can trust to paint it.

[Cdnpt1]

I have had success with jb weld, not the putty but the 2 part epoxy. The area has to be nice and clean, paint free and you will have to put it on so you end up with and even flat surface for the petcock to mate to. You can find it pretty much any autoparts place or Home depot/Lowes in the paint section I think. Brazing involves a torch and that will be a PITA as far as draining and rinsing the tank. letting it sit doesn't cut it, I have seen so called dried out tanks shoot a three foot flame and burst seams. As far as painting, did you check out the "how to paint your GS tutorial" ? Save you a lot of money if you are a DIY guy.

[Nessism]

How about taking some close up photos using your camera's macro feature and posting them up so we can see these grooves? Post photos to photobucket or similar, don't just attach them via forum link as that only allows low resolution photos.

If we can see what's going on it will help us offer a solution.

Oh, and good job figuring out what the root cause of the problem is. Now we need to eliminate the cause, not apply a bandaid (hopefully).

[spyug]

I have had similar issues in the past and my solution was to cut a larger gasket from a rubber bicycle inner tube. Size it about 1/4" larger than the outline of the p'cock base plate and of course cut holes to clear the filter and for the bolts. Leave the existing o-ring in place and put this gasket over it. Sand or grind down the grooves or fill with epoxy putty to get as flat as you can. When tightened down the gasket will fill and seal any imperfections.

For added peace of mind you can coat the gasket on the tank side with some gas resistant liquid gasket.

I did a friends bike this way 5 years back and its still fine and drip free.

Good luck with it.

Spyug

[bonanzadave]

Ive got some of that aircraft grade polysulfide (fuel tank sealer) I could send you....

http://www.ppg.com/coatings/aerospace/sealants1/ps_890_class_b.pdf