So i need to fix a motorcycle gas tank

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Sat for too long with some water in it and now has some real nice holes. I thought I was free and clear after peeling off the tank repair the PO did and brazed up the "little" holes. I started cleaning up around the repair and found much worse hidden under the paint. Any suggestions on how to fix this darn thing? Good used tanks are $300 on ebay. No way am i spending that. I bought the whole bike for $500 and had it running in 30 mins. I have oxy/act/map, miller 252, 250amp HF tig.I have pondered cutting a piece of scrap and stuffing it in through the filler neck and attempt to braze from the outside. I'm scared of not being able to form the metal to contour the curve of the tank. Last resort would be to use fiberglass but I don't like it and I don't want to destroy the outside look of the tank. Might just have to cut out the cancer and attempt to bang a piece of sheet into shape. At any rate I'm good at fixing pin holes or huge holes but not this size hole lolThanksAdam Attached Images
Reply:As is?Nope sorry can't be done.For the amount of crap you will encounter trying to repair something that is beyond repair 300$ don't sound so bad afterall......zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:If it's for riding, I'd braze a scab patch to the outside since "strong" trumps "pretty", spray bomb it whatever color is lying aroung the shop, and go ride while keeping an eye out for a cheap tank.If it's collectible, pay the nice man for a tank.
Reply:Make a new tank..... Or fiddle f&$" around and make a replacement patch, by that I don't just mean that little section though, cause by the time you go to welding it or brazing it you'll find it will be quite thin through out that entire side. If your not confident or able to basically build half of the tank, the only resort t to pony up the $$$$$. Hey the gubment prints it every day.Miller bobcat 225g  - spoolmatic 1Mm250 - 30a spoolMiller spectrum 375Thermal arc 95 Everlast Ex 250As the boiler turns, these are the days of our lives
Reply:As the saying has been told to me many times I'll pass it on "kid you polish a turd all you want, but at the end of the day it's still a piece of ****" Complement of my old man.Miller bobcat 225g  - spoolmatic 1Mm250 - 30a spoolMiller spectrum 375Thermal arc 95 Everlast Ex 250As the boiler turns, these are the days of our lives
Reply:I've inspected/repaired hundreds of mc tanks.You need to wire brush off--all the paint on the entire tank outsidelooking for more pinholes.Have the inside of the tank muratic acid washed and neutralized, theninspect tank i/s.The resistance welded seam is notorious for rusting, BTW.After all of the above, then decide if a patch job(s) will suffice.After patch jobbing, then coat the i/s to prevent further rusting.As others have said--first look is enough-that tank is toast.Last edited by dave powelson; 07-05-2012 at 07:44 PM.Reason: correction, addtitionBlackbird
Reply:I'll fix it for alot more than $300 most likely. Gotta weigh your options bud I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:I've done some pretty tedious probably not-so-smart things to some gas tanks. I have more time and tools than money so I'll give it a go and see how it ends up. Here's a flip side tank I did. Took 4-freaking ever but ended up perfect on the bike i built. I'll strip it down and check it out. It's already pretty shot so I can't mess it up anymore right?
Reply:Dished tanks are cool. I like the monoshock seat! Much cooler than old-school outboard springs.Bike has reasonable proportions too.Since you can do that level of stuff, consider a custom tank.
Reply:Thanks, I have never really done any sheet metal English wheel stuff. Do you have any DIY tank suggestions? I have 2 late 70's KZ projects I'm working on as well. This tank is off a 94' suzuki intruder 800 that is fairly stock. I bought it for cheap with electrical issues and sorted them out quick with intentions to resell.... The flip tank I finished was started by some one else because they needed to sand blast the inside to remove some old sealer and rust. Sealing that thing up was a major pain in the rear.
Reply:There's a shop in Auburn, WA called Bent Bike.  They have TONS of used stuff for motorcycles.  Wouldn't hurt to give them a call, tell them what you're looking for.  http://bentbikemotorcycles.com/  Good luck.  If you fix that tank, show us some  pics!-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:This one similar? Ebay tanks for Intruders aren't expensive.http://www.ebay.com/itm/1998-Suzuki-...be5b58&vxp=mtrAs for DIY, you might mock one up with posterboard and tape to see what you like.You might try these folks too, specifying you don't mind a few dings (lowers the price) but don't want rust:http://www.midscyclesalvage.com/
Reply:Originally Posted by adam90xjI've done some pretty tedious probably not-so-smart things to some gas tanks. I have more time and tools than money so I'll give it a go and see how it ends up. Here's a flip side tank I did. Took 4-freaking ever but ended up perfect on the bike i built. I'll strip it down and check it out. It's already pretty shot so I can't mess it up anymore right?
Reply:I'd be concerned about mice moving into the swiss cheese. That being said, what you show isn't the only hole. If it's rusted now, it will continue to rust. Ride down the road one day and you wind up with a lapfull of gas and onto a hot engine, too. Cycle Salvage + a $5 Tremclad rattle can would be my choice Might put you out $60 including tax, cheaper than welding gas, unless a MadMax tank (and mice) are what you're after. Either way, an interesting exercise Cheers!! When a welder tells you to "stick it", what do they really mean?"In a time of universal deceit, telling the truth is a revolutionary act." - George Orwell
Reply:Get a small hand held sand blasting gun, and some crushed garnet.  That'll uncover a lot of rusted pin holes for you.  You'll be suprsied.