Nice hole in gas tank

[nashville_bill]

I'm looking for suggestions on how to seal a hole in a gas tank. I hate to admit it, but I made the hole by forgeting a washer when putting the fairing back on my wifes Ninja 250. The screw will cut a nice round hole (there is a nice round flap that just folded back) in the tank if you forget to put the spacer in with the screw.

I don't really want to blow myself up with the gas fumes, but I do want to fix this thing. I think if I fill the tank with water, turn it so the hole is at the top and use a torch to heat the area and then solder the hole and flap closed, I'll be OK. I've read that you can really be surprised by the explosion in a tank, so I haven't tried to fix it yet.

Any suggestions would be appreciated.

[jetmechmarty]

Bill,

Have it welded by a professional. It will be fixed right and fixed forever. Don't waste your time or risk injury.

[MaximPhil]

Bill,

Have it welded by a professional. It will be fixed right and fixed forever. Don't waste your time or risk injury.

Hi Bill,
I agree with Marty. A friend tried solder to fill in a series of pinholes. had to braze it in the end. He discussed the theory of filling the tank with gas but also lacked the conviction it would work so filled with water in the end.
Phil

[jetmechmarty]

I'll add here that if you braze, it could lead to trouble with the paint.

[DGXSER]

You could put a liner kit in the tank. Fill the hole you have with Bondo or the like and then install the liner kit. JAT

[tarzan]

I have fixed gas tanks by rinsing out with water,blowing it out with air ,then let it sit for a day or so.No more fumes, or at least very minor.Never had one explode or even go wooooof.
This has worked for me, obviously you need to pretty sure it's cleared out well.
When I was a kid ,an older neighbor kid took dents out with gas.He emptied the tank and shook it with a couple drops in it, then dropped a match in it.It would have a small explosion and knock dents out. That was a little stupid.It seemed to work though.Just not very smart.

[prometheus578]

Sorry I didn't read this thread sooner

I believe this related to the Ninja 250.
Right before the shop closed down three/four years ago, there was a tech bulletin (I believe for the 250) concerning the fairing/fuel tank screws. Seems some clown at the factory put the wrong length screws in some fairings and that they were puncturing the fuel tank.

Customers were asked to bring their bikes in for inspection... which consisted of taking the screws out and measuring them to see if'in they were the correct length, etc.

Now... if your bike falls under the year/ serial number of the bikes for recall/inspection (which I don't remember) you may get a new tank out of the deal.

If you're not the original owner, Kawasaki may have no record of you and wouldn't have been able to send out a notice instructing you to bring it in for a look-see.

Head to a Kawa dealership with your registration or serial number and let them run it through the computer to see if you fell under the bulletin.

Now... If you put the wrong screw in the wrong hole.... or your puncture is in an area other than where the recalled screws would have punctured the tank... you're out of luck, I suppose.

Just a thought.


Just found a link to some weasel lawyer who does lemon law stuff. Lists some of the year/models for the recall
http://www.ohiolemonlaw.com/safety-r...-fuel-tank.htm