Gas Tank Repair

[rebelrider_68]

Well, I've found my first problem with my '86 Rebel project bike, albeit a small one. When I took the gas tank off, I scratched off some gummy-looking stuff off the tank, and out poured gasoline. It looks like the original owner repaired a tiny pinhole in the tank. My original plan was to use the original tank, but now I'm not sure if I should try and repair this one or just buy a new one. Any suggestions or pros and cons?

Thanks

[GearJammer]

It's really a matter of how much the repair would cost vs. buying a replacement gas tank. If re-painting is involved, it would obviously up the cost of repair, etc.

With this being an '86, am gonna "guess" that the leak might be near the rear gas tank mounting tab that sits in front of the rider's seat (but maybe not)....my '85 had some very slight seepage there & others have had leakage from that area due to the stress on the gas tank mount against the backbone of the frame. Of course, your's might be anywhere on the tank.......

Pinhole leaks or very slightly cracked seams can often be repaired by brazing. Larger holes would be better dealt with by welding & either type of repair must be done VERY carefully due to heat near gas fumes, so if you're not comfortable with doing it yourself, you can check with an experienced welder & most good indie shops should have a good welder available.

You could take the gas tank to a shop & get their opinion along with their price quote, then weigh that against the cost of a replacement tank.

[rebelrider_68]

Thanks, Gearjammer.

You're dead-on target with the location of the leak. If that were the extent of it, I'd probably opt for repairing the tank, but when I went to pour out the last bit of gas, what came out looked like bacon grease, so I'm just going to replace the tank.

[GearJammer]

Your choice will obviously be respected, but please keep in mind that the inside of the tank can be cleaned out, the leak near the tab can be welded & you could be back in business.

Sounds like there was a healthy supply of unhealthy gunk inside there, LOL! Does it look like a previous owner possibly attempted to use a tank sealant, but it didn't cure right due to improper tank prep before applying the sealant ?