Is there any saving this fuel tank?

[Folsoml]

Even a temporary fix? I'm thinking no.

[cb650]

Anything is possible. I wouldnt but they are getting harder to find and expencive.

[Volker_P]

This is a job for a welding artist. Or someone who likes to become one...

[trueblue]

If you can remove all the rust to get back to shiny metal you can lead wipe the tank to seal the holes, I did my 650 over 12 months ago and it is still good. One way to remove the rust is place the tank in a vinegar bath.

[Folsoml]

Here's what I'm trying. I got some JB Weld, but the holes are too big so the stuff just drips inside. I've shored up the holes with little wire mesh, and applied JB Weld on top of the mesh. I'll keep you posted.

[old gringo]

A hole that size on the bottom, plus possibly pin holes elsewhere, I would have it welded. Unless you are a very good welder which I suspect you may not be, then have a shop do it. These tanks are almost impossible to find in good shape so probably worth fixing. I like JB Weld but wouldn't trust it for this application. gas pouring suddenly onto the engine while you are astride the bike wouldn't be very good. Also, if you were to lay the bike down in an accident the tank would most likely rupture. Add sparks....

[Folsoml]

You are correct that I have no welding skills. I did not want to waste that tank because, other than what you see on the bottom, the tnk looks great.

If the JB Weld works, I was intending to use a tank sealant on it as well.

[old gringo]

You are correct that I have no welding skills. I did not want to waste that tank because, other than what you see on the bottom, the tnk looks great.

If the JB Weld works, I was intending to use a tank sealant on it as well.

Welding a gas tank takes skills that I do not posses either. I have used JB Weld on a small pin hole leak near the top of a tank once.

[Volker_P]

I have some experience with rusted stuff. My car is made of that...

So I think the points indicated below (and others looking similarly) will not be tight at all or for longer than a few weeks.
If you hit the left one with a hammer you will have a hole in there, just of the size like the one you plugged above with the mesh.
You may try out to get an idea that I know what I talk about if you like.

Sorry, your present efforts will in best case end up in a less leaky sieve but nothing one would like to call a fuel tank.

Welding rust to rust is within some limits possible with a TIG welder if you have some experience. This is the capability you need in this case.

Another option may be using the tank as a model for an epoxy cast. However epoxy tanks are tough (to impossible) with regard to paint them reliably.

[trueblue]

Here is a picture of mine once it was lead wiped, I dont have a before picture but pretty much the whole silver area was holes, it has been over 12 months since it was done and still no leaks. I wouldn't trust jb for that job, you could solder on some sheet to fill the larger holes.

[Folsoml]

I was afraid of that. Looking for another now.

[Volker_P]

For now I would not buy anything but just disassemble and analyze everything and make a list of unrecoverable parts.

With regard to your basis this list may grow very long. I would assume it soon will be of a length that would justify to buy a parts bike to shorten the search and to save money.

In this case any parts bike you can get would probably be a better basis.

....

My father would (seriously) solve your problem the follwing way: first clean it, then chuck it away!

[Bigg]

My father would (seriously) solve your problem the follwing way: first clean it, then chuck it away!

that's awesome advice!

[MEHall]

I Got a tip:
If you cant save the fuel tank so keep the mounting points and fit a new one on the remnants of the old.
Just a suggestion though.

[Folsoml]

My father would (seriously) solve your problem the follwing way: first clean it, then chuck it away!

The JB Weld dried and I added a quantity of mineral spirits. I found several pin holes that I missed. It looks like I'm going to do a version of your father's advice. I'm going to coat it in JB Weld, then chuck it away.