Small Hole in Tank

Paul75

Paul75

XS650 Addict
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Hey guys

Looking for some help here if possible, I've dug out the tank and found a small hole. For the most part (I'd say about 95%) of it it's actually sound but there is clearly rust in the area in the photo. From your vast experience what is the best/most effective way of welding the hole up? I've no welding experience BUT am thinking more and more about it as there are quite a few other things I'd like to fabricate. Any advice much appreciated
 

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garbage. the hole is just a small part of the rust. that whole area is wasted and too thin to weld to. it can of course be fixed, but will be more than it is worth.
 
What I'm saying there is only rust in this lower area of the tank, the rest is clean......good tanks fairly hard to find in the UK at present...
 
Yeah, that is not a small hole and the bad area is even much larger. Here in the states we have "radiator shops" that repair holes in radiators, most of these shops will also repair fuel tanks. These shops are experts at soldering and testing the repairs after soldering, brazing or welding. That's where I'd take this tank if I had no other option, then filler and paint or maybe just paint depending on the area.

Scott
 
No Welding experience.............Fuel Tank................Want to cut and weld.................=............No face, Hair, hands or life

All of this part would need to be replaced..........
T1 1.jpg
 
Another option.......Wash the gas fumes out, water, dish soap. Grind, solder on a patch, beat/dent the area lower than it was. Fill the area with chopped fiberglass filler, finish with plastic filler then use a sealer like RedKote inside the tank. Primer the tank but wait a few weeks before color paint.
 
i'm in the 'junk it' crowd. i gotta think even in the uk that you can find another xs tank or another model you can make work on your project. anything can be fixed but just need to figure if the time vs. money vs. value is worth it.
 
You are dealing with gasoline, and thus your life. I'm with Skull, I say junk it. Beyond repair. There are tons of XS tanks on EBay.
 
Cheers for advice here guys, the tank will go and I'll start the hunt for another. To widen my search, which tanks from other bikes work well on the XS...?
 
Yamaha XS750 tanks will fit with a bit of work and they're bigger too. Search on this site for instructions on how fit one - it's not too big a job.
 
Sweet....there is a guy near me who imports bikes from the States, gonna head there later!
 
He has nothing in at their moment and nothing decent on eBay in the UK at the moment.......do any other tanks work?
 
I assumed that you were able to access EBay USA, but that doesn't seem to be the case.

You might try taking measurements, then going to a m-cycle salvage yard, and trying to find something that would fit, and return it if it doesn't.

Otherwise, the above-mentioned option by Mr2wheel could perhaps work for you: >> Wash the gas fumes out, water, dish soap. Grind, solder (braze would be better) on a patch, beat/dent the area lower than it was. Fill the area with [ fiberglass matting soaked with resin ] , finish with plastic filler then use a sealer like RedKote inside the tank.<<
 
Hmm I don't think my skills are up to it......my local guy did have a tank for an XS850.....it looked huge so I dismissed it......was I wrong?
 
The Special tank would fit right on - but yes, the 850 tank would fit as well (from what I understand, they are the same as the XS750 tank...but that may NOT be correct and I don't want to give you a bum steer).

Pete
 
Photo taken through the petcock - rust only in very isolated area......
OI000001 (3).jpg


Photo taken through filler opening......no rust.....
OI000002 (002).jpg


Tank roughly sanded back........
OI000003 (002) - Copy.jpg
 
Had a more detailed look today and rust is literally only present around the hole, the rest of the tank is in remarkable condition for its age. How hard would it be for someone with experience to patch this?
 

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