*#%@*&^%!%#$!!!!!!!!!!!

[jetmechmarty]

I just lined a tank with the Caswell stuff. It wasn't difficult and it cures as hard as glass. Those holes will be no issue for that stuff. Just put tape on them.



Epoxy Gas Tank Sealer

I believe this would be your cheapest and quickest fix.

Phenol Novolac Epoxies are a new breed of chemical resistant materials, able to withstand permanent immersion of many harsh solvents, fuels and oils. This Epoxy has much better bond strength than single component products, with strengths of up to 3000 PSI, and this higher strength reduces the need for a clinically clean surface, as the epoxy actually prefers to bond to a rough rusty surface. Our new phenol novolac is more thixotropic, which means it 'hangs' on the tank walls during the coating process. This gives a thicker overall coating. There is more volume of material in the kit to allow for this.

[BA80]

Finally got the holes filled I'll have to bring the petcocks to work tomorrow and see if it's gonna hold.



Didn't hurt the paint real bad.

[Courtney]

Did I miss something? What did you do to fill the holes, weld, braze, or epoxy?

[BA80]

Silver solder.

[skids]

test with soapy water and air pressure?

[BA80]

I'll be testing it tomorrow. I'll put the petcocks back in and put some fuel in it. I had Evaporust in it for over a week before I painted it and it never leaked a drop until I but gas in it.

[WMarshy]

test with soapy water and air pressure?

Bad idea, you could end up inflating the tank.

[mmatches1]

I face the same dilema and decided to try the caswell kit. I cleaned the inside several times with acetone and plan to coat it tonight. I was then going to fill the pin holes on the outside with body filler and have the tank primed and painted. There have been many good reports about this stuff and there is an article in this months Canadian Vintage Motorcyle Group magazine about how to apply it. They key with this stuff is removing all gas residue from the tank with multiple acetone flushes. They discuss using it with a fiberglass tank but it should apply to metal as well. Here is what they say:

“Regarding Dick Cowling’s need to seal a fiberglass tank I’ve
found the best product is Caswell epoxy.
http://www.caswellcanada.ca/shop/epo...nk-sealer.html
The only problem I’ve seen with this kit is ensuring that the
tank is really clean and dry before putting in the sealer. I
disagree with their instructions to use paint stripper in a
fiberglass tank. In most cases it causes more damage. My
personal preference is to use acetone. Put in a pint at a time
swish it around and dump it out. Obviously the petcock has
been removed and the hole plugged. When you dump the
acetone it will have some colour from gas and oil residue
(especially those old Spanish two-strokes). Keep rinsing until
the acetone comes out clear. I’ve used up to a gallon of
acetone to fully clean one tank. I ignore more of Caswell
instructions and skip the water/soap/water rinse. Following
the acetone allow the tank to completely dry which may take
a day or so. Placing the tank out in the hot sun speeds
drying time as does blowing with an air hose, as long as you
don’t have any moisture to contaminate your nice clean tank.
Mix the epoxy as suggested by the kit instructions. I find a
small paint mixer on a drill ensures a good mix. Don’t waste
any time after mixing as the material starts setting up fairly
quickly. Dump it in the tank. Put a plastic
bag over the filler cap or get creative. I have
spare caps for doing the epoxy on my
Bultacos. Flip the tank every which way to ensure you get
good coverage. You don’t have to do this fast. In fact I find
doing a slow roll of the tank taking about a minute will
ensure it flows over all the internal surfaces.
When you think you have good coverage open the filler and
dump out the remaining epoxy. Allow the tank to dry completely
for 24 hours. Remove the petcock fitting plug and run
a drill through the epoxy layer. If you have crossover line
fittings they will need to be drilled out as well. Now the tank
is ready to be finished on the outside. The epoxy resists the
ethanol in modern fuels and even resists race fuel and other
nasty stuff that I use to fuel my old Spanish Iron.”

[BA80]

Well, I'm drying the tank again. Put gas in it this morning and it's still leaking around those 2 larger holes.

[jetmechmarty]

If your tank is painted and you don't want to mess it up, you had best wrap it up. That stuff doesn't come off.



Here is the whole story about fixing my tank:

XS650 Garage Tank Liner Failed

[Mr.Bill]

http://www.caswellplating.com/restor...nk-sealer.html

Looks like a nice epoxy sealer, that will fill holes.

[donebysunday]

http://www.caswellplating.com/restor...nk-sealer.html

Looks like a nice epoxy sealer, that will fill holes.

Used the caswell coating years ago, followed the directions exactly. I remember reading leave the tank cure for 3 days before using ( could be different now ? ), I did follow the directions. Put it all back together added fuel and within a short time the coating began to dissolve. Called caswell and they said you should leave it cure at least 3 weeks, I argued I followed your directions, they say we will send you a new kit. By the time the new kit came the coating was still soft in the tank, through it and the new kit in the trash. I admit it could have been my fault but I will never use it again. Por 15 is one I've heard was good and another at the farmers stores for tanks on tractors.

[skids]

Bad idea, you could end up inflating the tank.

I didn't mean inflate to 28psi. You could turn on your shop vac to blowing and that would be enough pressure to make bubbles.

[skids]

PS I inflated a tank once when trying to remove a dent and you are right....bad idea!

[jetmechmarty]

Used the caswell coating years ago, followed the directions exactly. I remember reading leave the tank cure for 3 days before using ( could be different now ? ), I did follow the directions. Put it all back together added fuel and within a short time the coating began to dissolve. Called caswell and they said you should leave it cure at least 3 weeks, I argued I followed your directions, they say we will send you a new kit. By the time the new kit came the coating was still soft in the tank, through it and the new kit in the trash. I admit it could have been my fault but I will never use it again. Por 15 is one I've heard was good and another at the farmers stores for tanks on tractors.

I remember you telling me that story, UD. The fact that it's epoxy rather than solvent based sucked me right in. I let it sit for a month before I put gasoline in it. So far, so good.