Help, Luckily I was so unlucky - nice hole in fuel tank!!

Have you seen the prices of new or even second handtanks? That will make you think twice about bying a new/replica. A competent sheet metal welder, with a knowledge of the precautions necessary when welding fuel tanks, can repair your tank fora fraction of that. I'm located in DK, so others must chime in with recommendations of specific companies or persons.

Bad luck Ashley. The first thing to do is to carefully examine the tank and find out just how bad it is! It would appear from your description that the tank has rusted tissue paper thin at the bottom, which would make it nigh on impossible to repair. If you have reasonably thick metal left, then just about any good car bodywork repairer could fix it for you.

Previously wrote:

Just got the MKIII out yesterday to check it over and clean it before the MOT on Friday. I noticed petrol dripping from the rear edge of the right hand seam, further investigation found the leak coming down the front right mounting rubbers around the stud. The tank was removed and the leak traced to what looked like the stud hole. I tried to unscrew the stud only to find that the stud fell into the tank leaving a 20mm nice neat round hole - yes, I only used my fingers!! If this had failed in use it would have been one expensive nut roaster!! I suppose a tank needing repair is far more enjoyable than a charred wreck.

So does anyone know of a company that could repair this, or is best to try and get a new tank.

Hello Ashley There is a nice new tank on Ebay in candy apple red , or you could send the tank to me as I am a welder that can weld to fresh air, I had years perfecting it and I have a Tank to do, I could do both in one go, if you need my email is annajeannette@btinternet.com Your AJD

I'd guess that this is an Interstate tank ? They are a bit known for damage around the front mounts. There is a lot of weight in a full Interstate tank and if that is coupled with owners sometimes leaving off the rear bracket as it's too fiddly and swinging too hard with a spanner on the front nuts, the result is often that the welded thread inserts tear out.

There is a good chance that rust is not the cause here and it's a pretty common repair and well worth doing. You might be surprised how little paint damage results. If your tank has any rust, that's likely to be on the back edge because Interstates tend to rub the saddles there - it's worth checking while it's off the bike.

It's always a good idea with questions like this to say where you're based.

Terry at 'Metal Magic' is ever so good. Be prepared for a culture shock when you turn into the farm and see his workshop but it seems a factor of the UK cottage industries that the best work comes from the most cluttered small shops.

You don't need to have any doubt about taking parts there.