Hole in a gas tank

[Guest]

What is the most effective way to repair a hole ( maybe .100 Inch diameter) in a gas tank?

[Nessism]

Epoxy putty patch from outside.

Derust tank with Metal Prep (available at Home Depot). You will have to make plugs for the various openings.

Seal tank with Caswell Plating gas tank epoxy.

[anthonygs1000]

What is the most effective way to repair a hole ( maybe .100 Inch diameter) in a gas tank?

Throw it out and get a good one ! this is the way I see things you can make hold gas again but is is safe ? (is the metal only week in one spot and are ya sure ) say low speed impact leaks 5 gallons spark if it does let loose, gas hot water heater or furnace in garage ! million of scenarios, cheep investment ! do it right the first time

ant

[MK3Brent]

No need to trash it, in my humble opinion.

Remove the tank, drain it, allow to dry, flush with water, dry in a climate controlled area, and weld the small hole closed with a TIG or similar fashion. (TIG because it's easier. MIG will do just as well.)

Smooth over the small hole, and you're just as good as new.

Very important to remove all gasoline, vapor, and any other inflammable liquids from any area you plan to weld.
Do so in a well ventilated area, and use common sense.

[anthonygs1000]

No need to trash it, in my humble opinion.

Remove the tank, drain it, allow to dry, flush with water, dry in a climate controlled area, and weld the small hole closed with a TIG or similar fashion. (TIG because it's easier. MIG will do just as well.)

Smooth over the small hole, and you're just as good as new.

Very important to remove all gasoline, vapor, and any other inflammable liquids from any area you plan to weld.
Do so in a well ventilated area, and use common sense.

I here ya with the weld up theory if ya can do it your self. if ya cant you have to factor in the price if the cleaning solvent $12.00 labor in welding $50 to $150 tank sealant $35.00 paint and body work $100 to $500

ant

[azr]

Epoxy putty patch from outside.

Derust tank with Metal Prep (available at Home Depot). You will have to make plugs for the various openings.

Seal tank with Caswell Plating gas tank epoxy.

Ed is speaking from good experience here, specifically to the type of hole that was described.

[anthonygs1000]

What is the most effective way to repair a hole ( maybe .100 Inch diameter) in a gas tank?

This is the hole you can see what about the ones ya cant ?

[koolaid_kid]

Anthony, the issue here is the rarity of these tanks. One makes do where possible, especially when funds are tight. Such is the way of the GSR.
I understand your point, but you must understand theirs as well.
The Caswell Plating gas tank epoxy will seal the ones that are on their way to becoming issues.

[MOC]

I had a similar problem. i removed the rust and then sealed the hole with brazing solder. i wanted something that was flexible and would expand at the same rate as the sheet metal so it wouldn't flake off over years of heat expansion/contraction. as long as you flux real well, it works great. i sealed the thing from the inside with caswell, and i'm in good shape:



after the patch:



and sealed with caswell:

[hampshirehog]

Solder or braze it. Maybe use one of the tank sealants that you can get in your area.

[chuck hahn]

IF you actually READ the Caswell INSTRUCTIONS..you know he paper that tells you how to do it..you will see that they suggest these easy steps.

Derust and prep the tank
Cover holes with duct tape
install the liner kit and let cure
Remove the tape and skim fill the outer side of the hole with body filler
Its really just that easy and it will work on holes as large as 2 or 3 MM easily
You do not need to weld, braze, solder. or anything else if you just do what the instructions say

[mash35231]

I emptied the gas tank in November. The hole is my fault...I was grinding the mounting away for the Suzuki badge. When I pulled the mounting off the tank the small plug where the tank/mount was spot welded came off with the mounting leaving a small diameter hole. The inside of the tank is rust free. The Casewell epoxy/liner sounds promising. I'll search where to purchase this product in the Dayton Ohio area.

[chuck hahn]

Now that I know what the holes are, your golden with the duct tape and liner. Then once its cured well some bondo and youll never know it was there. I would also suggest ( sort of along Eds epoxy patch ) that you save just a bit of the resin and the hardner.

Once you remove the tape, you will have a little left to paste into the holes from the outside as well. Let that help plug the holes as well and then bondo and finish it off.


Side note..Let it lay on the sides for a few extra seconds as you roll the tank to let the liner migrate around..that way it will be a little thicker on the spots where the holes are.

[chuck hahn]

You can review the product and application instructions here.

http://www.caswellplating.com/caswell-epoxy-gas-tank-sealer-motorcycle-tanks-up-to-10-gal-1-pint.html

[MOC]

IF you actually READ the Caswell INSTRUCTIONS..you know he paper that tells you how to do it..you will see that they suggest these easy steps...

You do not need to weld, braze, solder. or anything else if you just do what the instructions say

understood. just thought i'd contribute my experience.