vacuum petcock and gas tank issues - Honda Rebel Forum
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post #1 of 2 Old 05-20-2020, 06:41 PM Thread Starter
Join Date: May 2020
Posts: 1
vacuum petcock and gas tank issues

Hello all,
I'm new here and have appreciated the help I've already seen from this forum. I've been working on getting a 86 Rebel 450 going that my neighbor had lying around; I rebuilt the carbs last summer and cleaned up the gas tank some, but then I wasn't getting fuel into the system so I got a new vacuum petcock. (old one pictured below)

The new petcock is not compatible with the old tank! The attachment is too large. Also, after the winter, there are some new pin holes in the tank, and it even ate through the jb weld I had used to patch the last one. (pic)

So: what are my options?

1) Re-soak the tank to clean out rust, seal it properly, patch the holes (find someone to weld them?) Find a different petcock? Where can I get one?

2) Get the oversize 250 tank?

Thanks! Any help is appreciated.
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turtlepie is offline  
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post #2 of 2 Old 05-20-2020, 10:07 PM
Join Date: Aug 2008
Location: Monroe, Louisiana
Posts: 28,911
Welcome to the forum.

If there isn't a lot of loose rust in the tank, you can tape over the holes and line it with Caswell Epoxy Tank Sealer. It actually adheres to light rust better than bare metal. When applied properly, the tank will be strengthened by the epoxy coating and will never rust again.

The 250 tank will not fit without brackets. The Chinese oversize tanks have a tendency to leak along the poorly welded seams. Best fix is to line it with Caswell before ever putting gas in it. see this thread, and I don't like Kreem or any other flexible sealer.

Several members have used a Rebel 250 gravity fed petcock on their 450 tanks.

Keepin' all the left over parts. Gonna use 'em to build another bike!

'01 & '09 Rebel 250, '06 Ninja 250, '89 VN 750
Putting your bike year and model in your signature helps others help you!
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