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Discussion Starter #1
OK so I have all things buttoned up on the tank and Started the bike only to find a drip coming from under the tank. My initial thought was the o ring at the fuel pump but after further investigation I noticed it coming from the bottom of the tank at the factory crimping. Major bummed out. Is there a way to patch it or do I need to get a new tank? It is not a hole there, it is coming from where the tank is crimped together from the factory. I read on other forums where some people have patched these things with some Epoxy putty and other things even a bar of Ivory soap. Any of you have any thoughts? I think I am going to try the epoxy putty and see what happens. any help or thoughts are appreciated. Thanks in advance.
 

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Steel tanks can be repaired numerous ways, some of which you mentioned. Choose which one you feel is best for you but first check to see if it's caused by rust and go from there. (I have repaired leaking gas tanks on cars with a bar of soap, yes. :))
 

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I had mine welded around the edge of the seam after it slipped off the stand when full.
(I was cleaning the air-filter and had items on top of the engine which stopped it dropping onto its normal mounts so it fractured)
 

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I used the Caswells "Dragon Blood" to seal my st4 tank as it was rusty and had a failed linner when i bought it. Peeled most of the old linner out by hand then used solvents to remove the rest then chemicals to remove the rust. wash twice, dry with heated N2 then coated with caswell. So far its good but its only been 3000 miles.
 

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Often it's the spot welds to the hinge plate on the rear of the tank. I ended up welding mine myself from the inside. If I were to do it again I would use Caswell tank liner.
 

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FYI.... If you plan on welding do not forget about filling the tank with water within 1" of welded area....And of course the preferred way would be "tig" welding...

Or if the tank is really rusty take a look at what complete tanks are selling for on ebay, this "can" avoid a lot of hassles......
 

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Discussion Starter #8
So I finally got around to working on the bike again and the epoxy putty has seemed to work like a champ. I put it on there and let it set up. Man that stuff gets as hard as a rock. Put everything back on and hooked up and added fuel and no leak as of yet!:) I will check again when I get home from work. If all is well, then it is tim to pu the fairings back on and get a chain and sprocket set and I'm good to go for a test ride. I am sooo excited to ride this bike. I can't hardly wait.
 
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