Welding technique for pinholes???

[tkent02]

I have several gas tanks with tiny holes rusted through, always the lower left side. POs who park these bike for years never use centerstands it would seem.

The rest of the tanks are solid, I can use electrolysis to make sure all the other rust is gone.

I would rather be able to weld them than to use patches, putty, or other half measures.

What method and which type welder works the best for these tiny holes?

And I know about the Kaboom hazard, these tanks have been bone dry for years.

[teet]

I had inquired about having my holey tank from my other thread repaired by a welding shop.

They said it could probably be soldered, but tig welding it would be best, after all the internal rust was taken care of. They quoted me $50 if I cleaned it out first. I thought it was reasonable, but I happened upon a mint tank in the meantime...soooo

Jeff (teet)

[67fire]

Before welding any fuel tank, drop in a chunk of dry ice.
It takes all of the oxygen out.
We were moving a 20,000 gallon tank of ethanol (emptied) from Herndon, Va. to Fredericksburb, Va. for Virginia Gentleman Distillery back in '88? and the EPA guys were gathered around with their clipboards and such.
We dropped 500 Lbs. of dry ice into the tank and I questioned what they were doing. I was told to "just wait."
A few minutes later, a big geyser very much like Old Faithful happened and the EPA guys checked off everything and said that it was safe to transport as no more volatile substance remained.
I have since used that technic every time when welding a tank.

I was working for McGee's Crane Rental at the time as one of the two mechanics. I also drove the tractor trailer with the VHP escort.

Eric

[67fire]

Found it!

Bowmans had sold all but the farm’s main
house and the distillery to Robert E. Simon,
another visionary. He gave his initials to
Reston and in a sense fulfilled Dr. Wiehle’s
dream. Simon’s planned community was
built and prospered. By the late 1980s the
rapid growth of Reston and Northern
Virginia had convinced Bowman’s
executives to relocate to less crowded
climes.
The company purchased the former
FMD Cellophane plant in Fredericksburg,
Virginia. It had been vacant and
deteriorating for years. The Bowmans
restored the buildings, which held real
architectural interest, and converted them
to making and merchandising whiskey
[Figure 15]. The plant produces other kinds
of alcoholic drinks like gin and vodka, as
well as a higher quality, 90 proof bourbon.
The latter is sold under the Virginia
Gentleman label and is popularly known as
(what else) “The Fox” [Figure 16]. This
whiskey comes in a custom bottle with a
fox’s head molded into the glass and has
won the distillery national recognition for
quality.
At the time the Bowmans moved in
1987, they could boast that it was the oldest
family owned bourbon distillery in America.
In 2003, however, the operation was sold
to the Sazerac Company of Frankfurt Ky.,
who continue to produce Virginia
Gentleman as a popular brand of blended
whiskey.
William Lanahan and A. Smith
Bowman, in adjoining states, operated in
two different eras, one before Prohibition
and one after. Both, however, made their
love of fox-hunting an integral part of their
whiskey merchandising and found that their
symbolic cry of “Tally Ho!” brought fame
and fortune.
********

[reddirtrider]

I wouldn't try to bridge the pin holes with weld.

Instead, I'd cut or grind all of the rust out. What I'd do then is weld (or braze) another piece of sheet metal over the holes as a patch. They're on the bottom, so not much need to even try to disguise it. If it was on the side, I'd do the same then beat the metal down a bit and add filler to reshape.

The last step would be to coat the inside of the tank.

Oh, I just noticed you wnated to know what type of welder. NOT stick - lol. Try a wire feed or TIG. Wire feed being most readilly available - it's what I have. You could also braze the patch in. That solution would be pretty cheap. Go to Home Depot or similar, I think they have some units there. Note that the tank is pretty thin and you can burn through if not careful. Not nearly as thin as a Hyabusa tank though - I know from experience.

[Hammered]

Im welding up my old tank and heres the best Ive come up with after doing this kinda work for 25 years.

Thin ga. steel patches added to the outside with braze. If its rusted through, its thinned the steel in those areas of the tank. Id cut the patch about 1/2" or so larger than the area and braze one corner down. With a soft ehough hammer blow, tap the patch down and repeat until it in place. I say braze cause you have a far greater control over the heat than with any form of welding and I have a great little tig here to use.I wouldnt go thinker than 18ga. which you can pick up at your local Harry Homeowner store for under $10 or so. And they carry brazing rod. You will need to clean the area very good but you will much happier with the end result. Keep a bucket of water and a rag or two so you can apply a damp rag to the areas outside the welded area. This will lessen any warpage. Brazing is really easy and with a little Googling, you can find a bunch of quick Tutorals on "How To".