Motorcyle gas tank is dented, bike fell over, what is the best way to remove the dent?

Question

Honda GL 500I, tank is dented on the right side. Tank removal is easy. What is the best method and/or the easiest way to get the dent to "pop out"?

Answer 1

If the dent is only a depression without a crease either in the center or the perimeter it is possible to BLOW the dent out with compressed air. If there is a crease or a break in the paint it won't blow out. DO NOT drill into the tank to pull the dent out. You can possibly use a tool to push much of it out through the filler neck. Some bondo will be required to smooth out the dent followed by prime and paint. You might get lucky by calling 1-610-521-6700. They may have a tank for your bike undented and color matched.

Answer 2

EWWWW.....Ive got bad news my friend..depends on if the dent is deep,and is it creased,and has it dented where the tank folds. The real problem is the fact that most tanks have a double liner,meaning,what you see on the outside is not what the gas is actually being held,or contained by.
You can try to old method of blowing high compressed air into it and hoping it pops it out,you could try putting water in the tank and then putting the tank in the freezer,when the water hardens it expands and sometime its will push out a dent.
Dent pullers (suction cups) may work,and inexpensive.ive just neverhad any luck with that.
The most common way is to buy a new tank.

Answer 3

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RE:
Motorcyle gas tank is dented, bike fell over, what is the best way to remove the dent?
Honda GL 500I, tank is dented on the right side. Tank removal is easy. What is the best method and/or the easiest way to get the dent to "pop out"?

Answer 4

Just in case you didn't take blow torch as a joke. Don't use one!! Just as one answer said don't drill on your tank to try and pull the dent out, don't try to heat the dent to make it easier to work out. This is a gas tank and even empty the molecules and fumes get impregnated in the steel and can be volatile. There are options, carbon monoxide, water but unless you're a certified welder who has experience in such situations, don't do it.
My suggestion would be to take it to a certified welder and have him fill the dent with lead taking into account the size of the dent. Then bondo to smooth it out.
If you try to push the dent out from the inside I'd suggest a nylon tool. If you use metal you risk a spark and it doesn't take much to ignite gas fumes in an enclosed space.
My best suggestion is check some motorcycle salvage yards to find a used tank in good shape. One way or the other you're looking at a new paint job unless you get lucky at a salvage yard and find one with the same stock (I'm assuming) paint job.

Answer 5

I agree with the guy at the bottom, vacuum locked. That tells you why you had a dent. Also, it didnt start because the suction from the carbs could not overcome the vacuum lock in the gas tank. Fix the vents in the gas cap.

Answer 6

Your best bet is to just buy a new or used tank. By the time you pop the dent out, weld it up, and paint it you are looking at quite a bit of time and money.

Answer 7

depends on the dent.

If the dent is very rounded and gentle, I have wrapped a bunch of nylon straps around a tank (except where the dent is) and use compressed air to push a dent out.

Gotta be careful doing that, though, or you could explode the tank!

Otherwise, take it to a body shop and ask what they would do.

Answer 8

Bring it to a body shop.
They are professionals and can tell you whether the dent can be removed with a simple dent puller, or if it needs major work to fix it.

Answer 9

Get the right tool, an "L" bar with a flat or rounded end, fits in the fuel opening and just pry gently till it pops out, stop anywhere that sells body work tools, or an old biker.

Answer 10

Duh, with a blow torch?