Hello and a massive thank you to everyone here [UK]

[aviationfred]

Welcome to the forum 

By your posts it looks like you are on your way to a fine time of riding your FJ.


Fred

[PaulG]

I should have mentioned in the original post, the last owner bought a little book in 1994 and filled it with all the servicing it's done.  Everything down to when he changed bulbs, he clearly loved this bike and loved using it:

Wow. Those logs are a gold mine of information.  Even with sitting for the last decade, at least you know it was better taken care of than most people's kids. 

One other thing: get rid of the rubber brake lines and invest in a steel braided set.  Can't tell from the pic if it's been done already.  If you can, do this before your Euro tour.  They are affordable and the best safety improvement you could make.  Plenty of off the shelf units available, or even a local brake shop could fab you up a set, maybe for less.

Careful, this is one of the first steps into the rabbit hole of MODITUS....       bwwahahahaaaa...

[FJ_Hooligan]

I couldn't find any other pin holes and the ones that are there are currently patched with quicksteel epoxy resin.  So fingers crossed that's it.

Just thinking about it, once it's done and I'm ready to pour in the POR-15, do you allow it to go into the overflow and out the breather of the tank?  Just a bit worried I might block something up.

This is going to be a little hard to explain but I'll give it a shot.  When I did the POR-15 on a friend's tank, I pulled everything out and off of the tank.
I plugged the filler and sender holes with rubber expanding plugs and used cork plugs and tape on the gas cap, petcock and sender thread holes.  I think I taped up the oblong opening for the petcock, it's been many years since I did this. 

After doing all the prep work, when I was ready to add the actual sealer, I did so from the filler hole then used the rubber plug to seal it.  You then rotate the tank to distribute the sealer according to the instructions.  When finished, I pulled the sender hole plug and tried to get a much excess sealer out of the tank as possible.  You won't be able to get it all out.

I then propped the tank up on a wall with the front side of the tank down and the filler hole facing the wall and allowed the sealer to dry in that position.  This puts all the excess sealer in the expansion area of the tank and does not affect the fuel capacity of the tank.  Do not get the sealer in any threads or on the sealing surfaces of the sender or petcock.