Step 5: Repairing the gas tank
The gas tank had numerous problems. First, the inside was rusty and coated with 38 years of gunk. The petcock was clogged, and the tank had four dents in it.
Using a drill bit as a hand reamer, I unplugged the galleys in the petcock, then soaked it in carb cleaner.
For the inside of the tank, I first put a handful of nuts an bolts in it along with about a quart of degreaser, plugged the inlet and outlet, then rocked the tank back and forth and up & down for about 30 minutes to loosen the crud inside. Next I used a DIY commercial cleaning coating process which entailed soaking the inside of the tank in a weak acid solution for 8 hours, then using a neutralizer, then a permanent coating.
After taking care of the tank's insides, I then began work on the part that "shows." I used bondo to fill the four dents, carefully sanding and feathering the filler to the lines of the tank. Then I applied primer, then paint.
While the finaly coat was drying, I used a small knife blade to scrape away the rust from the tank's logo, then touched up the paint on the logo with an artist's brush.
Before reattaching the logo, I applied stair tread (sort of like a rough, rubbery tape) to the sides of the tank for decoration, then screwed the logo back on each side.
I realize this is not exactly how the original looked, but remember -- this is a resurrection, not a restoration!
Using a drill bit as a hand reamer, I unplugged the galleys in the petcock, then soaked it in carb cleaner.
For the inside of the tank, I first put a handful of nuts an bolts in it along with about a quart of degreaser, plugged the inlet and outlet, then rocked the tank back and forth and up & down for about 30 minutes to loosen the crud inside. Next I used a DIY commercial cleaning coating process which entailed soaking the inside of the tank in a weak acid solution for 8 hours, then using a neutralizer, then a permanent coating.
After taking care of the tank's insides, I then began work on the part that "shows." I used bondo to fill the four dents, carefully sanding and feathering the filler to the lines of the tank. Then I applied primer, then paint.
While the finaly coat was drying, I used a small knife blade to scrape away the rust from the tank's logo, then touched up the paint on the logo with an artist's brush.
Before reattaching the logo, I applied stair tread (sort of like a rough, rubbery tape) to the sides of the tank for decoration, then screwed the logo back on each side.
I realize this is not exactly how the original looked, but remember -- this is a resurrection, not a restoration!
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did you de-rusted your tank? I had the same problem. My tank was more than 40 years old. no paint, just rust. I did electrolysis on it. It looks awsome!!
You should try that if you haven't already. It really works wonders, and no fumes or harsh chemicals.
Here's the before and after. I just rinsed it with a hose.
yes i am restoreing a 71 honda rebel i am haveing trouble getting the tank to stop leaking.i have used marine tex,to stop all the leaks but new ones pop back up . there is a coating for the inside but i don't know what it is ,i can't afford a hunderd dollar coating.i got the rest going great. i will show it to you after it is finished. it stayed in the rain for over a year so i had some rust and other problems.like i had to use screen wire to cover some big hole in the tank. now it looks great but ............any advise be nice........