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Old April 18th, 2014, 08:36 PM   #1
Z1R rider
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Name: Roger
Location: Mitchell, South Dakota
Join Date: Apr 2014

Motorcycle(s): 1978 Z1R, 1999 EX250

Posts: A lot.
MOTY - 2018, MOTM - Oct '16
fixing a holed tank

the fixer I just bought had the dreaded hole in the gas tank from too long of a bolt, here's how I fixed it

used a spot weld cutter (a small hole saw in a drill) that you can pickup from an auto body shop.DSCF0030.JPG

after removing the threaded plate you have access to the hole to be repaired.DSCF0023.JPGDSCF0024.JPG

clean around the hole with sandpaper or emery cloth then cut a small chunk of sheet metal (clean this also) to cover the hole.DSCF0025.JPG


apply soldering paste to the tank and sheet metal and solder in place.DSCF0026.JPG






DO NOT USE A TORCH TO SOLDER!! Use a soldering gun, the small ones probably won't make enough heat to get the job done.DSCF0028.JPG


check to be sure you've got the hole sealed after soldering.

lastly solder the threaded plate back in place and your done.DSCF0032.JPG


by using a soldering gun you don't have the worries of a gas tank explosion like with welding or brazing.
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