Yikes, problems with rusty tank!

[Jethro]

I did a first flush last night, pretty much just put in a 50/50 mix of phos acid and water, about 2 1/2 gallons of the mix, 2 handfulls of 1/4" nuts, swished it around and let it sit for an hour while I smoked ciggs (away from the tank) and shaked it around every 10 minutes. What came out was a lot of little rust flakes, and the mix was real dirty. No real huge rust flakes came out, so that makes me feel warm and fuzzy. I flushed with water and dried like Billy, with paper towels through the sending unit hole and a heat gun set to low (and put outside for safety). After that the spots that were red and rust caked were no longer red, but still eveident. I'm gonna flush again tonight, after working a 16 hour day and see where I am at. I guess the real test will be how it all looks after sitting around all next week with a full tank of gas in it. I'll be away from the bike, so hopefully all will go well.

I have decided that no matter what it takes, I'll be going on the Cabot Trail run. Worst case scenario is that I have to micky mouse my 81 tank up to the 83 for the run. I don't care if I have to hook IV bottles full of gas up to the friggin' tank for the weekend. But based on last night's progress, I think I'll be fine. Let's just pray that no pin holes open up on me in the process. If they do, I have a Kreme kit that I am doing everything in my power to avoid using. My older 81 tank came that way and it was a huge, huge mess.

[beby99]

Don't forget to pack some bubble gum. Good luck.

[Jethro]

I have marine putty at the ready.

[lord1234]

jbweld and a coin works better than marine putty

[Road_Clam]

Looks like I have a date with Mr. POR-15.

Draining the tank into a funnel with a cheesecloth paint filter brought forth about 1/16th of a lb of rust. Nasty. Float bowls were FILLED with rust, it's a wonder I made it home. Anyone who has done the POR-15 job have some tips? Can it be done in a single evening? I have the tank drained and off the bike, sprayed some fogging oil in there for the time being.

If I can't get it done in a night, I'm out of the Cabot Trail run. I have no time between here and there...

When I prep my rusty tanks, I add clean, rinsed small rocks and stones with the acid. Then work the tank like your dipping pork chops in a shake-n-bake bag! This will help to dislodge stubborn rust you can't see. Rust ALWAYS is at it's worst down low in the seams (water is heavier than gas, and will always rot the very bottom of your fuel tank). Don't do my "pebble-prep" trick if you have a severely rusted tank, as it will most likely generate pinhole leaks where the rust has seriously devoured the tank.

[Jethro]

I used two boxes of 1/4" nuts in place of the rocks you mention. The tank is very solid, I think all the rust I am encountering is surface only.

[Jethro]

2nd treatment under way... let's hope she holds gas tonight!

[Jethro]

Well things look good. The inside of the tank really looks nice, no more rust at all. Thanks to Leo and Billy, I think the tank will be fine. I filled the tank with gas and not a single leak. The tank is defintely solid, it had just developed surface rust that was making quite a dust. You should have seen when I first shook around the loose nuts and bolts, then used the shop vac as a blower. Like red smoke for about 3 minutes pouring out of the filler!

That acid is nasty stuff BTW. Got some on my hands and OUCH! In about 2 seconds my hangnails were on FIRE. I hope the paint isn't gonna peel, I did get some of the water/acid solution on there, but I flushed it hard with water, then dried it perfectly and put wax on the tank. looks like it will be ok.

Glad I didn't have to use that Kreem!

[Billy Ricks]

I was happy with the results I got. Once I get things back together I'll probably do one more treatment to be on the safe side. If the tank had any old wax on it you should be fine as far as the paint goes. I got a little on mine and it didn't seem to hurt it.

[Can_O_Tuna]

Now you know what your smoking problem was !!! You were burning steel dust:-D:-D:-D

[jimcor]

I acid cleaned a tank, to protect the paint I covered the tank with Vaseline petro jelly. Makes it slippery, but the tank was safe from acid drips. Worked for me. Did make for a gooey clean-up, use Dawn detergent at the local spray car wash.