weld pin holes in gas tank

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Dude asked me if I could weld a "couple of pinholes" in a fuel tank, told him I'd take a look at it. When it came in I saw a few pin holes and the tell tale paint blisters all over. Handed it back and told him "its junk". Well he didn't want to understand, gave me the same look my dog gives me when I talk to her. So I pulled a screwdriver out of my apron pocket and put it against one of the paint blisters and pushed another hole into the tank. Still no understand! So I got aggravated and grabbed grinder with cutoff wheel and he looks concerned. Asked what I was going to do. Told him I needed to get a look at the pinholes from inside! I cut a section then buffed some fo the rust and let him look inside. Finally he understood. Tossed it into scrap iron pile, and told him to have nice day.Thats why welding pinholes in tanks is not a good idea. Its not about what you see on the outside.Peter Attached Images
Reply:10-4 to that. There is only 2 thing that make holes in a tank, rust and something got shoved though it. Only one of these worth fixing.Tough as nails and damn near as smart
Reply:dont ya love a show  with a good ending   made a  good call wish i coulda been there to see his EYES  when ya cutter openidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:What did the clown want you to do remove  the whole bottom of the tank and weld on a new bottom? Would be cheaper to get a new tank. Plus he really might want  to look into why it rusted and pin holed so bad so he can prevent that in the future.Co-Own CNC shop:Miller :1251 plasma cutter, MaxStar 700 TIG/Stick, & XMT 456 Multiprocess Welder.&  2 Hypertherm HPR260's Plasma CutterSorry I had a bad stroke but now I am back.
Reply:Great picts! I'll have to remember these for the next time someone here asked about welding up a leaky gas tank..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Originally Posted by tresi10-4 to that. There is only 2 thing that make holes in a tank, rust and something got shoved though it. Only one of these worth fixing.
Reply:There is a way to repair that tank but it does not involve welding,..There are many "gas tank liners" - that is a chemical that will reline the tank, covering and sealing the fuel from the metal.To cover the pinholes - using a high temparature soldering iron and some lead to melt a lead coat on the outside and then a bit of body filler.The reason for doing this is sometimes the bike is old enough that you can't find a suitable tank.Cheers
Reply:You are my hero!
Reply:Sometimes you gotta do what you can to save what you have. This was a tank from an older Kawi KZ 750. I didn't want to reuse it, but had no choice, as another one was not to be found. As you can see in the pics, I cut the bottom out inside the pinch weld, sandblasted the inside and welded it back together. Afterwards, I used the Kreem liner to prevent the inside from rusting again. Been 10 years and still holding up. Attached ImagesMiller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:The rest of the pics..... Attached ImagesMiller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:Originally Posted by paulmarrThere is a way to repair that tank but it does not involve welding,..There are many "gas tank liners" - that is a chemical that will reline the tank, covering and sealing the fuel from the metal.To cover the pinholes - using a high temparature soldering iron and some lead to melt a lead coat on the outside and then a bit of body filler.The reason for doing this is sometimes the bike is old enough that you can't find a suitable tank.Cheers
Reply:OH and by the way, if this was a Curtiss tank I woulda posted pics patching the tank!Peter
Reply:You did the right thing recommending the tank be replaced. For one thing, I noticed the newer bikes are built with tanks that are just about as thin as they can make them. That old Kawi tank I fixed was pretty beefy. Even so, if I could have found a replacement, that's the route I would have taken.The tank was water rinsed several times, then filled to the brim with water before cutting. The cutting was performed with a whiz wheel on a pneumatic die grinder. It was a bit messy with the water spraying everywhere, but there was (apparently) no danger of ignition. Once the inside of the tank was blasted clean, there was not the slightest hint of any residual fumes. The biggest challenge was refitting the bottom of the tank, as it sprung a bit out of shape after cutting / blasting.I am NOT suggesting or endorsing anyone else doing what I do, only telling what has worked for me more than a few times. Who knows, maybe I just got lucky. Maybe next time BOOM!Miller Thunderbolt AC/DC (Sold)Miller Dialarc 250HFMiller MM251Miller MM200 (Sold)Miller MM130Miller Spot WelderVictor O/A rigMiller Spoolmatic 1 (Sold)
Reply:Originally Posted by bratkid63You did the right thing recommending the tank be replaced. For one thing, I noticed the newer bikes are built with tanks that are just about as thin as they can make them. That old Kawi tank I fixed was pretty beefy. Even so, if I could have found a replacement, that's the route I would have taken.The tank was water rinsed several times, then filled to the brim with water before cutting. The cutting was performed with a whiz wheel on a pneumatic die grinder. It was a bit messy with the water spraying everywhere, but there was (apparently) no danger of ignition. Once the inside of the tank was blasted clean, there was not the slightest hint of any residual fumes. The biggest challenge was refitting the bottom of the tank, as it sprung a bit out of shape after cutting / blasting.I am NOT suggesting or endorsing anyone else doing what I do, only telling what has worked for me more than a few times. Who knows, maybe I just got lucky. Maybe next time BOOM!