busted carb?

[ozzstar]

I took apart the carbs to clean them today. The 1986 FJ1200 has been sitting for about 13 years with fuel in it, no thanks to the previous owner.  The fuel was past the terpentine stage and into the 'looks like thick black oil' stage.  Of course everything not covered in black goop was frozen in varnish.  Including the float bowl pins....and this is where the fun starts!!

After gallons of B12 Chemtool and PB Blaster i finally got all four floats out.  The problem is that in carbs 1 and 3 each snapped 1 post.  The posts were on the 'flange' side of the pin. 

Is there anyway i can repair the post in order to reinstall a new pin??  Or do i have to replace the carb body now?  O U C H

Because of someone elses neglect and me being determined to put this bike back on the road i've got a headache.  The bike is nearly rust free (except for the inner gas tank)and i didnt have the heart to sell it for parts. 

Any help would be greatly appreciated.  Any ideas or simple solutions?  Thanks in advance.

Ozz

[pdxfj]

Greetings Ozz

Brian Hunt and I ran into the same issues you have.  He picked up a '84 1100 that had sat for roughly 15 years full of fuel.  If you visit the FJ Rally site and go into the Misc section you'll find that we broke a float post also.

We tried some epoxy based stuff first that said it was fuel proof, and it worked great.  That was until the fuel ate the epoxy.  Brian took the float and post to a welder and they were able to tack it back on.  They had to use a high grade pure aluminum welding rod to bond with the aluminum alloys the carbs are made of.

A bit of grinding with a dremel to clean up the welds and it was good to go.

All hope is not lost.