Repair options - interstate tank

I have an interstate tank with micro-cracks around both front mounting bosses - yes, fuel leaks.
I think this is another example of where Norton did not do the "right thing" when increasing the mass of the tank by 2.5 times - cheapskates!
Anyway I have a tank with an excellent paint job that I need repaired.
Any suggestions?

I am currently thinking of grinding a "V" around the cracks, 90% filling the tank with water and TIG welding - followed by a TIG welded washer of appropriate size to reinforce the area.

Any experience? Better suggestions?
Cheers

robs ss said:

I have an interstate tank with micro-cracks around both front mounting bosses - yes, fuel leaks.
I think this is another example of where Norton did not do the "right thing" when increasing the mass of the tank by 2.5 times - cheapskates!
Anyway I have a tank with an excellent paint job that I need repaired.
Any suggestions?

I am currently thinking of grinding a "V" around the cracks, 90% filling the tank with water and TIG welding - followed by a TIG welded washer of appropriate size to reinforce the area.

Any experience? Better suggestions?
Cheers

Click to expand...

Rob,
Take a look at Fast Eddies post where he went to an Interstate setup.It shows how his welder reinforced the areas you are having problems.
Mike

My Interstate tank did the same so I cut out the threaded bosses & turned up some new ones, the head of which I made to the largest diameter that would fit. After flushing the tank out several times with boiling hot water & detergent I filled it 3/4 full with cold water, turned it upside down, fluxed the area, & fitted the top hats which I then silver soldered to the tank. If you have gas to spare, instead of filling with water argon could be used to purge the tank, whilst silver soldering/brazing/welding. This method means the whole area undrneath the inserts is joined to the tank giving maximum support. This is the method Homers should have used imo.
The other very important thing to do is have the tank sat on a firm length of foam rubber along it's underside to take some of the weight of five plus gallons of petrol.
I did this repair almost twenty years ago & it's still fine.

I'm prepared to be shot down here, but couldn't reinforcements be soldered in place?

cliffa said:

I'm prepared to be shot down here, but couldn't reinforcements be soldered in place?

Click to expand...

That is indeed possible, but soft solder could crack & may even be affected by petrol over time.

Mike writes: "
Take a look at Fast Eddies post where he went to an Interstate setup.It shows how his welder reinforced the areas you are having problems."

Mike, can you provide a link to that thread??

Stephen Hill said:

Mike writes: "
Take a look at Fast Eddies post where he went to an Interstate setup.It shows how his welder reinforced the areas you are having problems."

Mike, can you provide a link to that thread??

Click to expand...