one step fwd, one step back. fuel tank leaking from seam (?) whats my options here

hey guys.

the syncpro i have had the adapters jammed up inside it so i took that apart to get them and found there was still some fluid in it. i tried the tool and didnt do anything. BUT i was able to pull off one hose to use the built in restrictors with my vacuum guage and measure each carb individually find only one was off so only needed one adjustment. shes running pretty good but i can tell a proper sync will do better. had my friend test drive it when he came back around the tank is now leaking from the grommet ear for the side fairing under the petcock area. dripping pretty good so i got the tank drained out.

i know what red-kote is and am wondering if i should try it that way. i think this is one ill use evaporust in first.
is welding a possibility here? i know i could weld down the seam but would that stop the leak? i have to repaint this thing anyway... so my thought was to cover the tank in paint stripper and start over on it. theres already bondo/spot putty on it.

and if i do all of that... how i can i "shave" or get rid of the petcock so i can use an external shutoff. ive already had problems with it. if theres a way i can bypass it and leave it there for looks ill consider that as an option also.

what involved pulling the sending unit? it looks simple but is that another crazy expensive PITA ggasket there again too?

i just want to be prepared before i have to solve i problem i could avoid.

thanks a bunch guys.
vf700f 1985

 

I personally would never weld a petrol tank, though I'm sure many do and have methods to do it safely. I fixed the leaks on my Suzuki tank with solder and epoxy, which (touch wood) is holding so far. The biggest job is getting the area you need to solder clean, especially on a seam where the dirt/petrol is going to keep coming out of the seam.

 

As far I know the best way to render a petrol tank safe before welding it is to run a car exhaust through it for 10 minutes. In the past when I repaired a Suzuki GS1000 perforated tank I brazed it. Worked fine.
I then lined it with a UK product called Petseal which was pretty good.

 

well to weld a tank it just has to be dried out, but theres risk of fumes(the part that explodes, right) so you fill the tank with water. do your welding and get it dried out. i would do it but wanted to know if i welded up the seam if it would just cause leaks where i stopped welding lol.

 

Metal is likely too thin for welding. Your tank has rusted through. Best cure imo is the fuel tank sealer from Plating Kits Electroplating Kits Aluminum Anodizing Kits Powder Coating Systems Metal Polishing And Buffing Supplies - Caswell Inc


Until you've drained, flushed, de-rusted, and coated the tank, you'll have alot of problems with clogged carbs.