McGuyver this sensor -Om my

:ohmy:
While getting the rust out of my tank I disolved my fuel sensor and the plate was leaking with the new fuel so I had to act quick to avoid rust getting into my tank.
I noticed that the fuel was leaking from the area where the sensor. So I pulled/cut that area out and drilled with a 1/4 bit and the idea was to put a bolt tru there with plastic washers and an o-ring.

Fuel sensor before mcguyver


After drilling


first bolt, this leaked




second bolt try, this leaked less. There is a plastic washer on the outside and an o-ring nd thin metal washer inside. The problem is that the hole is not small enough and slightly square. Also the inside surface is not quite flat so I ground some of it to make a better surface but it still has a very slow leak.


I am using a 8mm bolt - my plan now is to tap a 5/16" or 3/8" thread. off to the hardware store.....very un-mcguyver

I originally was just goinf to post to document but now I'd like some thoughts if antyone cares to chime in.

I tapped a 5/16" hole and put a cap bolt on - this leaked a bit. then I used a plastic washer and seems better now. my other thoughts are:


epoxy weld to clue the hole shut? will this hold up to corosive gas?

maybe the leak is coming from the gasket -there is a rigde along the outside round edges but in the middle it is more recessed in the middle. I am not sure what it was like in the middle when the sensor was there.

Anyone?

Bueler?

Just as an aside, I've got to admire your determination; if that had been my tank, I think I'd have dug up a tee somewhere, taken it down to the local high school field and seen if I could kick a 50 yard field goal with it...

Be that as it may, how about a judicious bead - just a titch - of some likewise-rated silicone sealer around all the mating surfaces?

Epoxies, JB Weld, and all that stuff is great except for one thing: you get one shot at it. And first-shot kills haven't been the track record with this tank yet, so why expect anything to change now?

Wellm I am actually thinking of a new tank at this point, but where...ron ayers is probably thru the roof ....ebay? I'll post another pic .

I was thinking JBweld the hole which i have no use for anymore. my questions is weather it will hold for a long time...

Yeah, JB 'otter do it - just give it at least 24 hours to set.

Ebay, boneyards, maybe someone around here has a spare - they're all sources, just have to keep your eyes open...

JB Weld definately works great, just have to make sure you give it the 24 hours to cure. I have it in one of my float bowls holding the brass overflow tube together and has worked great so far(4+ momths). So I would assume it would hold just as great not being submerged in gas 24/7!:side:

I just ran into the same thing late last night. I finally was ready to start the bike for the first time since I got it in pieces last fall. I rebuilt the petcock with a Motion Pro kit; bad idea. leaked big time. Then the sensor began leaking. I drained the tank and went to bed. I was thinking that JB Weld would work, and I am glad I found this thread! Going to eliminate the sensor as soon as I get the JB Weld.
As far as the petcock, I am going with one from Z1 Enterprises that has on/off/reserve. I will add to this post as soon as the parts arrive.
Mark

Don't presume the JBweld will work. I used it on my gas tank, cleaned down to the bare metal, pushed in the JBweld, let it cure for days in a warm, dry spot, then mounted it and filled it with gas. It lasted for a couple of months, but then the leak reappeared. On examination, it was clear that the JBweld was decomposing at one spot.
/

there used to be a specific gas tank repair putty (two part mix together kind of stuff) available for cars - might try your local auto parts stores. it was similar to the jb weld stuff but meant for gas tank applications. I have used the stuff way back when and it did hold up to gas very well, but does need cure time, forget how long but should specify in the directions if you can get it.

good luck.