Dreaded leaking fuel tank

[gumby302ho]

 Checked in on my FJ today and was shocked to find the left side cover was bent and pulling away from a fuel leak from the tank. It was on its side stand when it happened. Its been fine all winter until this last week as I have been in the shop working on other things. I assume it is the dreaded pinholes in the seames down there but have not took tank off yet to see if a leaking petcock could flow fuel out that direction and destroy the side cover and paint on bottom left side of tank. This was upsetting to say the least. So my question would be whats a good fix to repair the pin holes. Thanks

[PaulG]

Can't help you with the pinholes, but I have many spare sidecovers. All red/white, though could be repainted as desired. Send me a PM if needed.

[fj1289]

Best option may be to find an old school radiator repair shop in your area.   You will have to drain and vent the tank really well.  Than have them braze it.  Will need to spot paint the area - but maybe it won't show behind the "new" side cover.  Anything I've ever tried like epoxy or fiberglass has leaked at some point down the road.   The best luck I have had was with traditional JB Weld - not the fast cure.   And VERY GOOD cleaning, roughening up, and prep work (applied to the OUTSIDE of the tank - NEVER the inside!)

Good luck.  Took me a long time to fix the same issue in my old XJ650 Seca - eventually gave up and found another tank. 

[FJmonkey]

Coating the inside will fill pin holes. A bit of work but the alternatives seem like an effort as well. Having a liner will also prevent rust from our Ethanol fuel.

[Motofun]

If you decide to coat the tank, I recommend Caswell for the job.  It's a 2 part epoxy that I've had great success with.  The better you clean the inside of the tank the better it works.

[gumby302ho]

If you decide to coat the tank, I recommend Caswell for the job.  It's a 2 part epoxy that I've had great success with.  The better you clean the inside of the tank the better it works.

I came across the caswell epoxy and from what I have read it seems to be a good product and they have mentioned its a good product to fix failed Kreem epoxy inside of tanks.  Thank you for the input gentleman, greatly appreciated. Stay safe