Motorcycle Gas Tank Repair | FZR1000 Restoration

Motorcycle Gas Tank Repair | FZR1000 Restoration - EP3

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Күн бұрын

The original gas tank was so badly (rust) damaged that I didn't think I'd be able to use it. I bought a spare gas tank as soon as one became available in hopes that it might be in better shape than my original one. These Genesis fuel tanks are quickly becoming unobtanium.
The original tank needed a lot of work - the rust was so bad that there were holes left in the tank after the paint stripping and acid dipping. The spare tank turned out to be in much better shape but still needed repairs before it could fend for itself in the wild. Both tanks are now prepped in a 2K epoxy primer but still need the cosmetic body work done before they can be painted.
A lot of people have mentioned the POR-15 tank sealer product and I considered that for the original tank. I'm not a fan of single part (air dry) products - they just don't have the long-term chemical resistance to fuels that contain alcohol. What I found was MAX GRE which is a two-part epoxy specifically designed in fabricating carbon fiber fuel cells and is completely resistant to all fuels (gasoline, alcohol, diesel, etc.). Since I have a lot of confidence encapsulating the tank with a fine fiberglass cloth, that's what I've chosen to do (I've built a number of boats). It may not be conventional thinking for motorcycle restorations, but for long-term results, I think this is going to work best.
Teaser at the end...you'll see what's coming next.

Пікірлер: 28

@jh-tech5546 7 ай бұрын

Hi Ken. Interesting technique with the cloth and epoxy on the outside. I can see the benefits of it enforcing the weakened tank. On the downside I suppose a lot of work to get the surface smooth again. Nice work so far. The frame looks stunning. It is going to be a beauty!

@KensWorldRestorations 7 ай бұрын

Yeah, I thought about so many ways to repair it but none made much sense both structurally and economically. I couldn't resort to metal repair and coating it on the inside didn't make a whole lot of sense to me. It was a lot of work considering the time it took but it's completely sound and I was able to retain the original shape (I've built a number of canoes and small boats). The inside is completely rust free and it weighs about the same as the other tank, so I'm guessing the lost steel (rust) was replaced by GRE epoxy and fibreglass. Overall, I'm confident that this tank can be used again without any problems although my choice to use the "yellow" tank for the restoration has been made. Thanks for the nice comment on the frame - that's all coming up in the next video.

@johnczirjak 7 ай бұрын

Very inspiring Ken! I can always learn something new from your detailed videos. Your first series of Virago vids are the most informative. I have an 86’ 1100.

@KensWorldRestorations 7 ай бұрын

Thanks John! The Virago was more of a learning experience for me too. First complete restoration. There's a lot of good information out there and the FB groups are pretty good too.

@Fireballspc 7 ай бұрын

Hi Kens... Despite being quite laborious, as expected, this restoration process is progressing well. This requires a lot of dedication and patience, which you have is plenty. This mptp will certainly look very beautiful. Hugs and see you in the next episode.

@joef6858 7 ай бұрын

Looking good Ken. You certainly have the dedication to finish a project.

@KensWorldRestorations 7 ай бұрын

I built a lot of models when I was a kid and this really puts me back in that state of mind. I love breaking it down into sections because it keeps me focused on an end result. I feel like I owe it to the world to bring these old bikes back to life because I remember what it was like when this was all new.

@ChrisSofos 7 ай бұрын

I admire your patience!!!😊😊😊

@KensWorldRestorations 7 ай бұрын

Thanks Chris!! Call it patience, call it OCD or just a wee bit crazy.

@yarekk 7 ай бұрын

Beautiful work Ken!!!!

@KensWorldRestorations 7 ай бұрын

You know you'll be tearing it up someday when I get it down to California!!

@yarekk 7 ай бұрын

@@KensWorldRestorations I'm not sure I can handle that kind of trust/responsibility, but I'd love to ride a piece of history like that. About same age as me, too!

@86AW11 6 ай бұрын

Looking forward to seeing more videos on the big FZR. Had a FZR600 myself that I traded in for a YFZ750. Haven't had a ride on a 1000 yet. Currently ride a 2000 VFR800

@KensWorldRestorations 6 ай бұрын

I can't wait to get back to some process on the bike. Turns out there's a lot of little things that are broken, bent, or just plain ol' MIA. I've spent a lot of time cleaning sub-assemblies like foot rests, fairing brackets, steering & suspension only to run into parts that are missing/broken and really hard to find replacements. It was -35C (-31F) for a week after I got home so I couldn't paint anything. I'll do my best to continue with the work since the frame is at a point where things should start going back on soon. I really want to ride this bike again. I LOVE the FZR600. Just something about the look and sound of that bike. Seems like you have a pretty sweet ride now. :o)

@86AW11 6 ай бұрын

I prefer the older bikes, less electronic gizmos and I like the styling of the mid 80s-90s sportbikes. EFI does beat messing with carbs though. Had a few RZ350s back in the day. A few Honda Nighthawk S' even a 74 Kawi Z1. Should have kept a few of those.

@KensWorldRestorations 6 ай бұрын

@@86AW11 Your handle Old Rotorhead...pretty cool. If I could find a 74 Z1, I'd keep it hidden for a while...if you can find one at all now. Crazy!

@86AW11 6 ай бұрын

@@KensWorldRestorations You in the rotary wing business? Saw a license plate on the wall with Heli on on.

@KensWorldRestorations 6 ай бұрын

@@86AW11 Yeah...that's a real California plate. Couldn't believe it was available (1997) when I moved to San Diego. Put it on my Jeep and the back plate was stolen a week after I got it. That's my reminder to myself that even when I think the odds are slim, I do it anyway. I fly the S92 offshore these days.

@rgmax6205 7 ай бұрын

I'm looking for a 89-90 FZR1000 myself and found your channel. You do excellent work, can't wait to see how this turns out. Good call on using the second tank, a lot of rust in the original one. Not sure I would trust it not to develop a new pinhole somewhere else in the future. The frame turned out fantastic! Are you planning to do a video on that? I have to know how you went about restoring that.

@KensWorldRestorations 7 ай бұрын

Thanks for the comment - I was considering a '90 as well. I just love the look of the updated body work, tank and swing arm on the Exup years. I think you'll find that there's a bit more support, parts and options in the way of the later Exup models. The Genesis was only made for two years and already I'm finding the same problems I ran into with my '84 Virago. The first gen carbs are completely obsolete (post '89 parts are still readily available), tire sizes in a matching set are nearly impossible to find and just finding engine parts (pistons, rings, etc) in general are more of a challenge. As for the frame, yes! I've got a lot of videos of what I've done so far and will be making one on my cleaning/restoring process. The frame and swing arm were actually anodized while a lot of the hardware (brackets, steering parts, etc) were painted silver with a clear coat. Probably a month's worth of work just cleaning hardware but it's coming along. So far the frame has been washed and the anodizing removed - that's why it looks so bright. I still have to repair the road marks in the swing arm and do some minor refinishing to the frame before I get them all vapour blasted and either matt 2K clear or re-anodized. Probably the next video in this series.

@uhtred7860 7 ай бұрын

Aww man that tank! 😧 My tank has a couple of small dents in it from when the guy I bought the bike from, didn't secure it in his van when dropping it off, and it fell over. But it is rust free (well, serious rust free) I bought a mint tank off Ebay from the U.S a few years back that wouldn't have even needed painting, it was so good. But U.S customs seized it, and crushed it..... lesson learned, the hard and expensive way. My headlights were also in a state, someone had lost all the springs that keep tension on the adjusters, and replaced them with ball point pen springs😮‍💨, Luckily i found a NOS shell at CMSNL and all the springs and plastic adjuster nuts etc, I only used the headlights themselves, the rest is all new. Your frame looks like new, is that its final finish or is there a coating to go on? The red wheels for the N-American market was a thing done by the N.A importers/U.S Yamaha (there is no Yamaha part number for red wheels, only for white and silver/grey ones) This was probably done to try and associate the model with U.S rider, Eddie Lawsons YZR500 GP bike. The rest of the world got White or gray depending on what colour the bike was. Also, have you seen a product called POR-15 fuel tank sealer? A very good product.

@KensWorldRestorations 7 ай бұрын

Yeah, it was awful. There was no way any liquid tank sealer was going to work on it. Just way too many holes. And I’m just not a fan of the single stage sealers which is why I got in touch with the company that makes the 2 part epoxy. They’ve been making fuel cells with this stuff for years (including alcohol) so I was pretty confident doing it this way. The frame has been cleaned and the anodizing removed by a commercial anodizing company here in Calgary. I might have them re-anodize it after I’m done with the scratch removal or I might do a 2k satin clear. Haven’t decided yet. Sucks about your tank…can’t understand why customs would crush it…that’s criminal. The wheels will be powder coated white by a pro wheel place…I won’t be painting these myself.

@uhtred7860 7 ай бұрын

@@KensWorldRestorations Concerning the tank that was crushed, Customs said it "smelled funny" which is weird because the seller had vacuum packed it in a special plastic bag meant for vacuum packing things, and wrapped it in two more plastic bags plus loads of bubble wrap. Customs also cited something about it being "dangerous goods". What U.S customs SHOULD have done is return it to the sender, NOT crush it. I was left out of pocket, and it wasn't cheap. I know other guys who have had tanks shipped and they said the secret is, NEVER label them as a "Fuel Tank" always label it as "Motorcycle Parts" and make sure there is ZERO odour.

@KensWorldRestorations 7 ай бұрын

@@uhtred7860 That sucks. Yep - I've learned the "motorcycle parts" trick a long time ago. We get hammered here with duties from the US. I was pretty sure we had a trade agreement but I can get stuff cheaper and faster from China, Japan or the UK than I can from the US. I got stung hard with $200 on brokerage fees, taxes and customs costs on $200 worth of parts from Florida. I got what I needed but now I spend considerable more time digging into the cost of importing.