Aluminum gas tank dent repair

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Buccaneer
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Joined: Mon Mar 09, 2015 9:34 pm

Re: Aluminum gas tank dent repair

Postby Buccaneer » Sun Nov 12, 2017 8:13 pm

I played around with the tank a little more after
supper. Seeing how I'm now concentrating on
little dents instead of massive ones, I used
a brazing tip. Got quit a few smaller dents
out, but some are there to stay.
I went from 6 or 7 psi to 8 to 8-1/2 this time
will no ill effects, then again, I have no idea
how accurate my gauge is.

Anyone ever "bondo" just where the decal
goes for a nice flat surface for the decal,
and polish the visible aluminum areas?

Don't think I'll worry about a "better" tank.
Just as soon save my money for a tiller handle!

B-Dittmar
Posts: 59
Joined: Tue Mar 10, 2015 10:25 pm
Location: Oak Grove Minnesota

Re: Aluminum gas tank dent repair

Postby B-Dittmar » Sun Nov 12, 2017 8:18 pm

Hay Buccaneer If you ever get down to the north metro area I would be happy to teach you how to weld alum with a torch.
A.K.A Chrysleroutboarddude

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Buccaneer
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Joined: Mon Mar 09, 2015 9:34 pm

Re: Aluminum gas tank dent repair

Postby Buccaneer » Sun Nov 12, 2017 10:19 pm

Thanks for the offer Ben. I've tried welding a few aluminum
things with results from "poor" to "okay".
Guess I should practice on some junk gas tanks this winter.
Maybe you'll do a YouTube video on welding this winter
now that the lakes are turning to hard water!

B-Dittmar
Posts: 59
Joined: Tue Mar 10, 2015 10:25 pm
Location: Oak Grove Minnesota

Re: Aluminum gas tank dent repair

Postby B-Dittmar » Sun Nov 12, 2017 10:46 pm

Buccaneer wrote:Thanks for the offer Ben. I've tried welding a few aluminum
things with results from "poor" to "okay".
Guess I should practice on some junk gas tanks this winter.
Maybe you'll do a YouTube video on welding this winter
now that the lakes are turning to hard water
!

Well I have already made a video. But I am getting much better at welding them up now after doing 100+ of them I even did 6 of them tonight.
Hear is the video. https://youtu.be/igT70TT33t0
A.K.A Chrysleroutboarddude

B-Dittmar
Posts: 59
Joined: Tue Mar 10, 2015 10:25 pm
Location: Oak Grove Minnesota

Re: Aluminum gas tank dent repair

Postby B-Dittmar » Sun Nov 12, 2017 10:50 pm

Maybe I could stop buy sometime also to show you
I get in the Grand rapids area all the time.
A.K.A Chrysleroutboarddude

outbdnut2
Posts: 531
Joined: Wed Apr 27, 2016 2:46 pm

Re: Aluminum gas tank dent repair

Postby outbdnut2 » Sun Nov 12, 2017 11:29 pm

Steve A W wrote:Wow!
I didn't know there was anything like boat demo derbies. :shock:
LOL
That poor motor had a hard life.

Steve A W



I believe most dented tanks on old motors came from bouncing around in the trunk of a car. Back then, almost nobody owned a boat, but people bought motors and you could rent a boat on many lakes and put your own motor on it. Some were permanently stored in the car trunk, except when on a rental boat.
Dave

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Tubs
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Re: Aluminum gas tank dent repair

Postby Tubs » Mon Nov 13, 2017 10:46 am

Buccaneer wrote:Anyone ever "bondo" just where the decal
goes for a nice flat surface for the decal,
and polish the visible aluminum areas?



You have done really well with what you
had to start with. I suspect you have a
ton of time in it to get where you are
now. Bet you have learned a lot. I'm
guessing your success will motivate you
to try another. The more of them you
do the more you learn and the better
the result. You have to enjoy doing it
though because it takes a lot of time.
If your decal is one piece your likely
going to have trouble on the corners
as the surfaces is now curved so you
might try to see if you can get it flatter.
This tank had a real nice top so I got
the sides as flat as I could. Then I
fill and painted them.

Tank.jpg
Tank.jpg (530.89 KiB) Viewed 85 times

Tank 2.jpg
Tank 2.jpg (245.05 KiB) Viewed 85 times
Image Image Image Image

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Buccaneer
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Re: Aluminum gas tank dent repair

Postby Buccaneer » Mon Nov 13, 2017 12:15 pm

Tubs, I probably have 3 hours into the tank now
from when I started degreasing it. I have lots
of time, a fair amount of patience. Now
if I just had more energy and money!

I was looking at the tank this morning and thinking
about the very thing you mention, about
the decal being "problematic", seeing how
the back of the tank has a slight compound
curve now. I'm afraid if I try to flatten it in
one spot, that it's going to "buckle up" in another.
Garage is heat up now, so will go play some more!

I like your "Junkyard" outboard. I wish I would have
went to school to be a graphic artist...... would then
just painted "Johnson" on the back of the tank and
not worry about a decal!

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Garry in Tampa
Posts: 2182
Joined: Mon Mar 09, 2015 2:32 pm
Location: Florida

Re: Aluminum gas tank dent repair

Postby Garry in Tampa » Mon Nov 13, 2017 3:58 pm

A lot can be done with the photo enhancement software available for your computer. It just takes time and patience. Like the taxi driver told the person who asked how to get to Carnegie Hall - Practice, practice, practice . . . :D
Image

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Buccaneer
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Re: Aluminum gas tank dent repair

Postby Buccaneer » Fri Nov 17, 2017 4:38 pm

Finished on the A-80 Johnson to the point of running today.
Started on the second pull. Only ran it about 20 seconds
as it's a fish out of water. Further running will probably
be next May :-(

May order a decal and "bondo" up the tank where it goes,
and leave the top "A Naturale", and try polishing it if
I get some better equipment. The little two inch buffing
wheel in my drill don't "hack it"!

The last hurdle on this "well used" Johnson was the prop.
The shear pin groove inside the prop hub was wore
about twice as deep as original, causing the prop hub
to rub on the gear case.
Ended up making a new groove 90 degrees to the old one.
Seemed to do the trick!


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