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Leak fuel tank
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bullitt1964 View Drop Down
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    Posted: 13 Mar 2026 at 14:59
Hi guys bought a metal 99 fuel tank for my 2005 tuono  
had it resprayed and put decals on fits lovely put some fuel in to check for leaks minute pin hole leak🤬.
Is this repairable or has anyone tried these resins you swirl around tank .
The tank inside didn't look that rusty,think I'm going to be out of biking for a while any help and advice greatly appreciated many thanks dave
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Spoonz View Drop Down
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Personally I wouldn’t trust any kind of sealer long term. Maybe take it to a fabricator and ask what they can do without the heat damaging the paint too much or distorting the metal. Maybe brazing or something. 
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bullitt1964 View Drop Down
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Thanks for reply, I'm going to ask at a metal 
fabricator monday see what they suggest 
cheers dave 
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bullitt1964 View Drop Down
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Does anyone have a fuel pump flange base,I had to drill through the overflow pipes on mine to fit the overflow pipes i got from ap
is it possible to plug these so I can use my plastic tank for now cheers dave
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Spoonz View Drop Down
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The overflow, likely vents the tank so if you block it your tank may have a problem venting vapour/pressure as fuel expands or the level changes etc. 
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redratbike View Drop Down
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Originally posted by bullitt1964 bullitt1964 wrote:

Does anyone have a fuel pump flange base,I had to drill through the overflow pipes on mine to fit the overflow pipes i got from ap
is it possible to plug these so I can use my plastic tank for now cheers dave
just use the vacuum type bungs with the wire clips on 

Or some fuel proof hose with bungsand clips 


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bullitt1964 View Drop Down
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Thanks for reply guys will bung vents and let you know what happens about metal tank cheers dave
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bullitt1964 View Drop Down
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Points: 173 		Post Options Post Options   Thanks (0) Thanks(0)   Quote bullitt1964 Quote  Post ReplyReply Direct Link To This Post Posted: 17 Mar 2026 at 17:31
Hi guys have had the tank done at fabricator near me 
took it in morning picked it up a couple of hours later 
Looks good what they've done he tried to keep minimal 
damage to paint thanks for advice 
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redratbike View Drop Down
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Good news 

Where was it leaking at the front ? 


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bullitt1964 View Drop Down
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bullitt1964 View Drop Down
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Looks a nice job only charged me £20 thanks again for reply
It's taking me ages get this pic on here lol
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bullitt1964 View Drop Down
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bullitt1964 View Drop Down
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Here's what it looked like a small pin hole would have thought the guys spraying it would have noticed hopefully fixed nowThumbs Up
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Nice job 


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bullitt1964 View Drop Down
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đź‘Ťgoing to see what they'll do about paint 
I don't reckon they'll need to spray whole tank again surely hope not
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