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Old March 15th, 2019, 09:12 PM   #1
Danger4u2
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Name: Dave
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Repair/Prep f/ IBA ride

My 2006 Ninja had been sitting inside for 2 years when I bought it. It had rust in the tank and needed a battery. So that's where I started, new battery and removed the tank. The first issue I found was a hole in the tank on the top right faring screw.
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Old March 15th, 2019, 09:40 PM   #2
Danger4u2
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It was missing the spacer and I can't imagine the screw piercing the tank without striping the phillips head or at least messing up the threads on the end of the screw. The screw was in perfect condition.
But I still have a hole in the tank. Here's how I fixed it.
I took a plastic coated steel garden stake for tomatoes and bent it in a J shape so I could back up the hole from the inside. I put a piece of masking tape on the end for better grip. Next I threaded the screw in the left side and bottomed it lightly against the tank. I wrapped it with a narrow piece of masking tape as a depth gauge. A Q-Tip is just the right diameter to reach thru the threaded flange and pack the hole with J-B Weld (cut the cotton tip off). I needed a second person to hold the stake backing up the hole. Then I took the depth gauge screw and greased the end. I didn't want J-B Weld sticking to the end of the screw but I wanted it to stick to the treads. I screwed it in and out cleaning the threads each time until both the screw and tank flange threads were free of J-B Weld. I greased the end of the screw again, inserted it in the hole using the tape as the depth gauge, removed the stake and turned the tank screw side down so the epoxy would stay in the hole against the end of the greased screw.
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Old March 15th, 2019, 10:23 PM   #3
Danger4u2
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The J-B Weld worked great. It made a good bond, I think it will hold well. If not I'm no worse off than when I started. The alternative is to cut the spot welds of the flange without cutting into the tank and tig welding the hole. That might involve plastic bead blasting the tank and repainting it.
So on to the rust issue. I made a petcock block off plate to cover the petcock hole, making a gasket from thin rubber. I used gas line for 2 of the 3 smog tubes capping the center one with a vacuum port cap. Then I added 1 gallon of vinegar, two cups of 36 grit aluminum oxide (Alox), topping it off with another gallon of vinegar. Alox is the same material they put on sandpaper and the vinegar is 5% acid to eat the rust. To give the Alox the grinding action it needs I stuffed the tank in a padded cement mixer. I put the tank in, filler neck first and let the mixer run for one hour level with the ground like the tank sets on the bike. I swapped the tank around and let it run another hour. I'm letting it sit over night then I'll run the mixer at a 45 degree angle for a half hour then swap ends for another half hour. The tank doesn't have cancerous rust so I won't need to coat the inside with any epoxy material like Cream tank coating. If all looks well inside I will rinse 3 or 4 times trying to remove all the Alox, then neutralize the acid with Arm and Hammer baking soda and water. Then I will rinse two times with real hot water. That will heat the tank speeding the drying process. Last I will use a compressed air nozzle in the petcock hole and put a shop vac in the filler neck.
That should do it. It's a long process but the cost is no more than $25 dollars and my time. Next....carb cleaning.
Post Script: The cling wrap was used to cover the gas fill hole. I folded a piece 4 layers thick, a little bigger than the gas cap, laying it over the hole and locking the gas cap to keep the vinegar from leaking out of the vent hole. The quarter is sitting in a small amount of the 36 grit Alox.
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File Type: jpg 20190315_165928.jpg (88.1 KB, 5 views)
File Type: jpg 20190315_170606.jpg (103.6 KB, 2 views)
File Type: jpg 20190315_194057.jpg (75.7 KB, 3 views)

Last futzed with by Danger4u2; March 15th, 2019 at 10:36 PM. Reason: pictures
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Old March 16th, 2019, 06:55 AM   #4
dodgerdad
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Interesting science. Can't wait to see the results!
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Old March 16th, 2019, 08:04 AM   #5
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Here's how I fixed the hole in mine. The tank metal is very thin, a person could probably run the screw through it just thinking they're tightening it, hence the reason for the spacer for it to bottom out on.

https://www.ninjette.org/forums/showthread.php?t=176379
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