popping dents on a gas tank

so i was considering how to pop the dents on my gas tank and someone told me to plug the cap with a plumbing plug and run an airline into the petcock pipe.

i was wondering if you had better suggestions before i did that or worse by using bondo. if i chose the bondo im also considering knocking the emblem mounts in and filling them for a nice smooth look. but considering the condition of the bike (stock and all original) i am hesitant about the modification.

I would first try dry ice on the dented area(fuel removed of course) then let the sun hit it. Dings and small dents should come out nicely.

please explain further.

just place dry ice on it to super-cool then let the heat hit it to cause expansion and contraction of the metals?

how long should i let it sit with the dry ice on it?

Air in the tank does work if you heat the dent, use low pressure (10psi or so max, go slow and make sure the tank doesnt split, fold backwards, tear or crumple...

Or bend up a pipe that will fit to the back of the dent and pop her out from behind. Stud welders suck for kz gas tanks the material is to thick and you wind up pulling the stud off and leaving a pin hole

im trying to not damage the original paint if possible.

Till its frosted. This works for superficial dings and dents. Not sure wat you have in the way of dents. You may have to go further like Flovianus says if the dry ice trick doesn't work. If you look online, there are written procedures and hundreds of YouTube vids.

i took the shots so you can see the dents. there are a few more but they are minor.

The steel on a motorcycle tank is heavier gauge than that of auto body panels..so some dent removal tricks don't work too well...but you have nothing to lose so try them. I would counsel you to be sure about filling in the badge mounts...that is a one-way road. I'd be leery of taking a collector bike (KZ900) down a one-way customization road.

green is dent locations and the yellow is a deep scratch and i cant tell if its base paint or rust, lol

Mcdroid wrote: I'd be leery of taking a collector bike (KZ900) down a one-way customization road.

exactly.

Scratches your at the mercy of the paint damage. Start with rubbing compound and see where you can go. As for the dents as well start with the ice and progress your repair to your satisfaction. I echo wat McDroid says and DO NOT fill in the badge mount. You will regret it later. Heavier gauge metal may take longer dry ice soak time. You really have nothing to lose.

thanks guys, ill update as i find time to do the work.

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