Tank Liner Issue

[MPittma100]

I have recently encountered a Venturer fuel tank that was previously lined with a yellowish colored liner. The liner has begun to release from the tank in small pieces. The pieces end up at the petcock filters.

I need to know what is the best way to remove the remainder of the liner and what type of new liner should be reinstalled. The rust in the tank's interior appears to be light surface rust - not that bad. I need to be sure that I do not harm the paint on the tank exterior.

Also, one of the plastic filters from one of the petcocks was loose in the tank. Any suggestions on how to hold it onto the petcock would be appreciated. It is a little loose as is and will not stay on by itself.

Thanks in advance.

Mike

[jetmechmarty]

Mike,

I just went through this and posted on one of the XS650 forums. I'll share here.

Failed Tank Liner

The important part is to protect the paint, and that is covered in the above thread. Also, I tried paint stripper first. It made a mess and didn't work. I recommend you try acetone or MEK first. If it was a solvent based liner, either of those should dissolve it. Those resin removal media from Harbor Freight cleaned it all up.

Contact me, and I'll talk you through it. Read my thread and avoid my mistakes.

[skids]

If you don't mind messing up the paint job, use acetone and lengths of plant-hanger chain. Turn the float assembly backwards (inside-out) and use a piece of innertube as a gasket. Remove the petcocks and use flat stock with a gasket (I used big orings). If you use nuts as abasive material, you will never get them all out. Chain is easier to snag. This work for me with the rubbery tank liner that was in there.

[D0wn5h1ft]

If you don't mind messing up the paint job, use acetone and lengths of plant-hanger chain. Turn the float assembly backwards (inside-out) and use a piece of innertube as a gasket. Remove the petcocks and use flat stock with a gasket (I used big orings). If you use nuts as abasive material, you will never get them all out. Chain is easier to snag. This work for me with the rubbery tank liner that was in there.

Also, don't use little fish tank pebbles (this was recommended to me). There is still one of those ******* flying around my gas tank that I will probably never be able to get out (even after the hour and a half I spent trying to get all of them out).

[vedgar]

same problem

I will wait til spring when the weather is warmer. Filling the tank half full with acetone and then rotating it slightly will work . I put a piece of the liner in a capful of acetone and the acetone destroyed it. I also want to save the exterior paint. cover with plastic wrap and metal tape. BE CAREFUL, acetone is highly flammable and should be used in a well ventilated area. Not the basement in the winter.

[jetmechmarty]

If you don't mind messing up the paint job, use acetone and lengths of plant-hanger chain. Turn the float assembly backwards (inside-out) and use a piece of innertube as a gasket. Remove the petcocks and use flat stock with a gasket (I used big orings). If you use nuts as abasive material, you will never get them all out. Chain is easier to snag. This work for me with the rubbery tank liner that was in there.

Acetone or MEK will not harm the paint if necessary precautions are taken. Fuel cocks and sending unit must be removed. Abrasive media is easy enough to remove.



I used the clothes dryer after packing the tank in a few sleeping bags.

[vedgar]

King Tut

Wow what a wrap job ! King Tut should have it so good.

[jetmechmarty]

Wow what a wrap job ! King Tut should have it so good.

The paint was new and I was using paint stripper in my first attempt to remove the liner. I thought the multi layer wrap was appropriate. The important part is that it worked.

[vedgar]

wrapper

Gonna do it just the same as you

[jetmechmarty]

Gonna do it just the same as you

Be sure to go to my Failed Tank Liner link and read through it. I think the details are pretty well covered.

[MPittma100]

Update Tank Prep

My tank update is that I have tumbled the abrasive stones through the tank via clothes dryer. (Don't tell my wife)

This process really smoothed and finished cleaning the tank's interior since the removal of the old liner with 2 applications of acetone.

I currently have the Metal Rescue in the tank doing it's job and I will determine what to do next (liner or no liner) after seeing the results of this step.

Here are acouple of pix showing the abrasive stones before (green) and after (rust). Looking closely at the rust covered stones you can see some of the liner pieces that refused to let go with the acetone.





Thanks to all of your suggestions especially to Marty whose help has been invaluable.

Mike

[MPittma100]

Update Tank Prep

My tank update is that I have tumbled the abrasive stones through the tank via clothes dryer. (Don't tell my wife)

This process really smoothed and finished cleaning the tank's interior since the removal of the old liner with 2 applications of acetone.

I currently have the Metal Rescue in the tank doing it's job and I will determine what to do next (liner or no liner) after seeing the results of this step.

Here are a couple of pix showing the abrasive stones before (green) and after (rust). looking closely at the rust covered stones you can see some pieces of the old liner that refused to let go when I used the acetone.



Mike

[vedgar]

abrasive stone

wher did you purchase abrasive stones ?

[MPittma100]

Abrasive Stones

wher did you purchase abrasive stones ?

These came from Harbor Freight. They are called Rust-Cutting Resin Abrasive Tumbler Media. The part number is 60542. Comes in a 5 pound plastic container. Price is $19.99.

Mike

[MPittma100]

Metal Rescue Results

The Metal Rescue has been at work for a little more than 24 hours now. Instructions say no longer than 48 hours. I have checked it's progress a couple of times. It is doing a good job - all the way down to "new" metal.

Looking forward to a like-new tank.

Mike