Gas Tank Restoration Details

Contrary to popular belief, there is no special tool that goes into the neck of the tank and pops out the dent nor is there a magic suction cup. Welding a rod to the damaged area then using a “slap hammer” to pull the dents out would be fine if your tank was steel, as thick as a fender on a 49’ Mercury and you were going to fill the low spots with led. Repairing an unpainted aluminum vintage motocross gas tank requires patience and experience.

My technique for restoring aluminum gas tanks is known as panel beating and it’s been performed by exotic car restoration shops on aluminum body panels for decades. Much like removing the skin of a fender or door of a car for repair, the underside of the tank is removed to access the inside of the dented area. The damage is worked from both sides with special hammers and dollies until the metal is re-shaped closely to its original contour. Upon the area being close to perfect, a lot of time is spent hand sanding to level any uneven areas. This is followed by polishing to insure the repair is perfect.

On tanks with marble sized dents, in certain cases the tunnel may not be removed. A small access area is opened, the repair is made, the hole is welded and the tank is ready for polishing or paint. The aluminum gas tank on your Honda Elsinore 250, CZ Falta replica, Maico, BSA, Triumph etc. will look like new. The same method is applied to painted aluminum tanks where dents are exceptionally large or deep.

Average cost for single color tanks: $475.00

• 1977-79 Honda CR 125-250
• 1974-78 Kawasaki KX 125 250
• 1976-79 Maico painted aluminum
• 1968 and newer Yamaha DT, RT, MX
• 1974-76 Yamaha YZ 125 250 360 400
• 1972-77 Suzuki 125-250-400 TM-RM
• 1972-76 CZ steel or painted aluminum
• 1974-5 Honda CR 125-250 & Husqvarna

Above tanks slightly higher