How clean and seal gas tank?

In process of building an xj550. Anyone have tips on cleaning and resealing a gas tank or is this something i should let the pros do?

 

POR-15 seems like a good system, you could check that one out.

 

If the tank has been sealed before, you have real problems. If not, follow the POR-15, or similar, instructions to the letter. It takes about a week to do it properly.

 

its the factory tank from my 82'. I just think it should be gone through again seeing as how its almost 30 years old

 

Por-15's HD kit comes with a stripper bottle incase it has been sealed before. I have the kit but not started yet.

 

The POR-15 kit worked good, even tho a little time consuming, but plugging the holes so the solutions would remain in the tank while being sloshed around was a PITA.

POR says to use duct 'or something similar,' which worked fine for the petcock & level sensor openings but not so hot for the filler hole.

You may want to figure out a good solution for that before you begin.

 

Thanks for info.
I have "blocker gaskets/plates" from XJ4ever for this purpose. I have some ideas for the filler hole and protecting my paint, but time will tell...

 

Don't seal it up too tight while the sealer is curing as it may explode.

 

I just finished doing a very rusty 750 tank, ended up using the KBS system, clearing the rust was PITA but in the end it was worth it. It took about a week to de rust and de varnish/sludge the tank, I wanted that thing as clean as possible. The KBS system seems to have set up very well, although I haven't put fuel in the tank as it has just finished its cure period and I'm not quite ready to put it back on the bike. I can say that the sealer that got on the rubber stopper I used to plug the fuel filler hole has a very tough flexible coating on it now that is very resistant to anything pushing into it.

 

I did the POR-15 with my Seca tank about a month and a half ago. Happy with it so far. I purchased a blanking kit from XJ4Ever for the sending unit and petcock. I also removed the gas cap and put and expandable rubber plug in. Your going to be shaking the tank hard to get these chemicals in every little spot inside the tank. you also do not want this stuff to get on the outside of the tank if possible. One thing they stress before putting the sealer in is the tank must be bone dry or it will not cure correctly. I ended up putting a hair dryer at the gas cap hole and a shop vac drawing the air out at the sending unit opening. I did this for a number of hours. Just make sure it is dry. Also if you use the blanking plates once the sealer starts to dry back out the screws and remove the plates or you will never get them out. Clean the threads for the sending unit and petcock so they dont get sealed close. i just used cuetips. One other thing, make sure you put in new rubber mounting seals for the sending unit and petcock when you reassembly the tank.

 

Where did u get expandable plug and what size range?

 

thanks everyone for the info. Sounds like the por-15 kit is the way to go. i looked on their site, does everyone get the big kit for $77?

 

Don't remember what size I used but the kit was $44 TMD thru Amazon.

 

I also got from amazon.

The step one (stripper) bottle had leaked inside the 2 factory sealed boxes. But I got a replacement promptly from the seller. (Only seems to be on on Amazon).

 

Metal_Bob, I got the plug from McMaster-Carr. I measured the larger diameter of the gas cap hole (It is cone shaped) and looked on there webpage for a little larger diameter rubber plug that was adjustable with a center screw and wingnut.