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Old 08-11-2011, 02:12 PM   #1 (permalink)
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Default Help! Punctured gas tank - 07 ZX6R

So, I did one of the dumbest thing I have ever done in my life. I lost one of my fairing bolts that connect the black plastic piece above my side fairing to the gas tank so I got a replacement screw (not exactly the same...longer) and screwed it in. Well, I guess I didn't notice that I screwed it through the gas tank so the next day I smell gas in the house. Well I check the bike and find a small puddle of gas underneath my bike...pinpointed it to the screw and started to unscrew it which created a flood of gasoline to come out. It looks like its mostly drained out now but what can I do to inexpensively fix the puncture? I read that I can take it to someone to weld it shut but is that the safest and cheapest way? Any other ideas?
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Old 08-11-2011, 02:44 PM   #2 (permalink)
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It's thin steel, so it'll have to be a really good welder. Cheap-o fix that I would suggest: J-B Weld. Clean the area thoroughly, sand the tank down all the way to the metal at least half an inch or so around the puncture. Put down a glob of J-B Weld and smooth it out the best you can. When it dries you can sand it down flatter (gonna need some harsh paper). When it's as flat as you can get it, then put a sticker over it. LOL. I would have suggested a fiberglass patch, but I don't know if fuel will mess with the fiberglass and deteriorate it over time.

Search for a welder first I guess and see how much they want to charge. Good luck.
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Old 08-11-2011, 02:55 PM   #3 (permalink)
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It's thin steel, so it'll have to be a really good welder. Cheap-o fix that I would suggest: J-B Weld. Clean the area thoroughly, sand the tank down all the way to the metal at least half an inch or so around the puncture. Put down a glob of J-B Weld and smooth it out the best you can. When it dries you can sand it down flatter (gonna need some harsh paper). When it's as flat as you can get it, then put a sticker over it. LOL. I would have suggested a fiberglass patch, but I don't know if fuel will mess with the fiberglass and deteriorate it over time.

Search for a welder first I guess and see how much they want to charge. Good luck.
Ok, so duct tape is out of the question, I kid I kid. hahaha.

I guess this will take off the tank and see if there are any welders in the area that can do it...if not, JB Weld it is.
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Old 08-11-2011, 02:57 PM   #4 (permalink)
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Ok, so duct tape is out of the question, I kid I kid. hahaha.

I guess this will take off the tank and see if there are any welders in the area that can do it...if not, JB Weld it is.
Yeah it sucks, but it'll at least let you ride and get money together for a replacement tank. Good luck. I bet Whitehendrix here on the forum could fix it for you, but you'd have to mail it to N. Carolina. That guy is an artist with a welder.
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Old 08-11-2011, 03:51 PM   #5 (permalink)
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new tanks r fkn expensive. when i went down on my 09 it scuffed the side of my tank n had a pinhole leak, looked into it 700$ for a new tank !
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Old 08-11-2011, 04:12 PM   #6 (permalink)
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scuff around the hole, coat a self-tapping screw with JB, screw it in, wait overnight...done.
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Old 08-11-2011, 04:14 PM   #7 (permalink)
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ebay a scratched or dented tank. put a green bandaid over the imperfection and call it a day.

yeah that is how hardcore guys roll, or well that is how i roll *wink. it doesnt look bad.
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Old 08-11-2011, 04:48 PM   #8 (permalink)
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If you do decide to get it welded keep in mind it'll have to sit outside for a least a week with the gas cap open. Applying heat to a tank of gas can have some interesting (explosive) consequences.
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Old 08-11-2011, 05:43 PM   #9 (permalink)
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If you do decide to get it welded keep in mind it'll have to sit outside for a least a week with the gas cap open. Applying heat to a tank of gas can have some interesting (explosive) consequences.
i take it this is from personal experience?
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Old 08-11-2011, 06:13 PM   #10 (permalink)
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Common sense.

That and I worked as a mechanic at a bike shop that had a full time body/paint guy. And he'd take in a gas tank then let it sit for at least a week outside after he drained it before he'd even consider sanding the damn thing let alone any sort of welding or brazing on it. Made sense to me, a small amount of gasoline vapour in an enclosed area plus heat is going to be remarkably unpleasant to be around.
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