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78 gs 1000 tank rehab

chuck hahn

chuck hahn

Forum LongTimer
Past Site Supporter
I got this tank many years ago from someone on the forum. Once i burned the old liner out and stripped the outside down I found it had been brazed along one side. Nothing wrong with that except it was left an absolute mess before it was covered in Bondo. Tank didnt leak with water in it so the braze job indeed did completely seal things up. So there was some "finishing" to be done.

First i took a double cut 3/8 burr in my die grinder and smoothed the leading edge so it resembled some sort of straight line along the crimp. Sorry..didnt take a picture of that. Next I filled in the side with JB Weld. This will accomplish three things. First it will fill in any pinholes in your tank once youve repaired any holes. Second, it will be a built up base for sanding and doing the basic recontouring of any affected areas. And third it will reinforce the area above and beyond what the tank liner supplies.

Not gonna bother with the under side as its not visible anyway.

I will post pics after sanding the JB Weld and detailing the bottom edge leading to the crimp.

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Whoever did it did a fine job of patching them but it wasnt cleaned up very well after. Its all good though now.
 
Have you got another GS1000 hidden away someplace, Chuck ?. Another resto thread, i liked your last one. Merry Christmas.
 
No on another bike. I have been looking for a 79 tank and Bomber 737 needs a 78 tank. He has a 79 tank so we have emailed back and forth and once thgis once got the Caswell tank liner in it Im gonna send it out and he will send me the 79 tank.

My plan is to then source a 79 tail cowl. I have side covers and a fender already so Im gonna paint a red set of Cooley body work. Take my OEM blue and white off and wrap it up and store it away. Make my bike a red Cooley. If I ever sell it the buyer will get the original blue body work and have the option to buy the red as well.
 
Used the palm sander to clean down the JB Weld I used as filler in all the waves from the brazers work. Still gonna need a skim coat of Bondo and some fine tune detailing. Rinsed the tank well with a strong mix of water and Muriatic Acid, rinsed well again with water to rinse debris out, then held it in front of the torpedo heater and rotated it to dry the inside extremely well. Caswell tank liner is in and its dripping into the trash can right now. Will take some pics after it has dripped a while and started to set up.
 
Sanded area with 80 grit. Gonna need a skim of Bondo to do final detailing. The acid cleaned the tank a bit where it spilled to the outside. This tank will not leak again for the next 30 years...
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