Auto Body - How-To repair a BIG dent on the side of a Harley-Davidson fuel tank

If you’re getting into repairing and painting motorcycles, you’ll surely come across having to repair a dent like this one.
This video show how I repair a large dent on the side of a Harley motorcycle tank.
PLEASE NOTE: This is a last resort fix if a customer cannot find another tank or doesn’t want to spend the money to purchase one.
Obviously if a good tank can be found, you should use that instead (be sure to consider the inside of the tank (if you can see it). These 2000-2003 Harley tanks had issues with the sealant peeling. 2004, H-D no longer used that sealant.
This large dent was repaired by just filling.
Make sure the customer knows up front that you are just filling it, if they ask but let them know that you just aren't filling it with bondo.
I’ve done MANY of these type dents using this method in the video without any issues.
Once this tank was repaired, the complete set was painted in Vivid Black basecoat/ clearcoat
Bonus showing toward the end of the video on saving a decal and factory stenciled eagle on the side of a tank
A couple tips and tricks.
#motorcyclepainting #motorcyclerepair #autobody
Be sure to “Like” and Subscribe to my channel.
*Subscribe* More vids coming soon!!
kzbin.info?s...
My Channel - / tazattitude
My Forum - www.custompaintforum.com/forum/
#custompaint #autobodyrepair #autoprep #carpainting Some of the products I used in the vid (Products avail for purchase on Amazon click to find out info and reviews on the products)
(Products avail for purchase on Amazon click to find out info and reviews on the products)
Icing Putty - amzn.to/3BKpScm
Soft Block - amzn.to/3BKpScm
Everglass - amzn.to/3Ug7hMp

[@nathanrichardson7706]

This is a great video of what not to do

[@scottf4249]

Like I mentioned in the video, it's a last resort fixt if you can't find one and if you do, it's either rusted inside of the sealer is peeling. Or both. Sure, if you can find a NOS for a $1000-$2000 go for it.

[@chadburns76]

I clicked on your profile so I could see the video of what to do but it wasn't there? Was it taken down?

[@Giitzerland]

as long as the other side of the tank is good(to get a profile template from) this is a pretty straight forward job, you always have a second chance to fix your flaws, if you don't get it right.

[@jasonkurtz3131]

Thank you for making these videos. I love learning and building my skills painting and doing body work and your videos are some of the most useful out there. Thanks

[@scottf4249]

Thank you Jason!! Glad you are enjoying and learning! I appreciate the compliment! I'm going to start getting back into doing the vids. Had to take a LONG break since my wife passed away

[@overtimecuztompaint]

Exactly.. never have I ever used that type of wheel to sand or grind 😅

[@Giitzerland]

This is a good business to be in, there is definitely no shortage of dented tanks :D When it comes to certain tanks like the Honda VTX 1800, even a used tank can be $1.5k, this is way more cost efficient! Fuel cap. will be reduced, but not by enough to worry about, but take it into consideration when you're on long log rides, and trying to time your stops with a group.

[@scottf4249]

Definitely, especially these 2000-2003 carb tank among others.

[@3613jeremy]

I feel ya on that my 09 Yamaha raider has a dent in the tank after my accident last year and they told me there was no guarantee I'd even get the tank and it would cost $2300 and if I was lucky I would get it the following summer.

[@lukehonerlaw3592]

Going to try this on my 02 ninja 250. Very severe dent, cheapest tank available is 900$. Thanks for video as i was feeling rather hopeless

[@TAZattitude]

Thank you. Grind the area VERY good. Use everglass or duraglass, then bondo to finish.

[@3rekoatskustoms929]

You do some amazing work thanks for sharing.

[@TAZattitude]

Thank you very much!

[@robertmahaney2854]

Thank you for the video ! Also when you pulled them in the past was the bubbling caused from fractures starting to leak fuel ?

[@scottf4249]

From the stud gun. Either from the studs being spot welded to the tank, or the process of pulling on the stud.

[@TAZattitude]

77451 (Gray) 77453 (Buff color) - 77457 Hardener I personally like the buff color. Seems just a tad bit thicker.

[@juliebrown9543]

Thanks great info so you don't weld studs and use a dent puller ?

[@TAZattitude]

Hi Julie. I don't use a stud gun anymore on the fuel tanks. Some tanks DO have a hole on the top so you can at least beat out some of the dent from the inside.

[@otee453]

Thanks for the video. I’m needing to fix a dent in a Harley tank and was debating trying to pull the dent or just fill it. Do you ever get any shrinkage or ghosting on a thick repair like this?

[@TAZattitude]

Not that I'm aware of. It's important to be sure to grind a big area and feather your edges before you start applying anything. It's normally the rough edges that come back. Be sure it's a factory paint job. More than one, and you should strip. Also be sure and let each coat harden good (everglass, bondo, primer....)

[@otee453]

@@TAZattitude awesome. Thanks for the tips and the video.

[@iJusTBlaZee]

I may need your services! I’m in Tampa area and would like to know where you are located?

[@sll-tt6bj]

Really enjoyed the video after you do all your Bondo work did you spray an epoxy sealer to cover any bare metal spots

[@TAZattitude]

Appreciate that. After the bodywork, I sprayed a 2K primer. Then I sprayed a sealer right before painting. Pretty much ALL jobs I do seal with a wet on wet sealer. I used to use Shop Line sealer, but they seem to have a very hard time getting that. I switched to TranStar. I get the white, lighter gray and black. I use the black on black or dark colored jobs.

[@sll-tt6bj]

@@TAZattitude thanks I appreciate the reply can I ask you what brand of candies and clear coat you use would really like to see a video on intertwining ghost flames that go under and over I paid a few motorcycles to supplement my income and also use the Dyna glass on big dents works great

[@TAZattitude]

@@sll-tt6bj I normally use House of Kolor candies. I do have a job coming up that has 'overlaying' flames' (two flame jobs).. But they are not not intertwining. I haven't done a job like that for quite some time. May do a separate panel on that. Glad you like this video. I believe you meant DuraGlass

[@Rick-Williams59]

Excellent repair.

[@TAZattitude]

Appreciate it Rick

[@milwaukeegregg]

What is the charge for this work??

[@findthehero]

On my tank there’s a faux gas cap on one side. They made a 1/8” ish deep indent with a 2 1/2” diameter from the factory to accommodate it. Is this a good method to use to fill that area and eliminate it?

[@TAZattitude]

Sure, you can fill this. I would recommend, grinding that complete area including the very corners, then filling with Duraglass or Everglass, Be usure you really smear in your first swipe, then fill the rest (with the same batch). Let dry for a bit, sand with 40, then coat with bondo. Look for pinholes and refill if necessary. You can completely swipe with flowable putty (like ICING)

[@joef6858]

What is this flowable putty (icing)?

[@belloautomotive1522]

Do you have a part number for the high tech primer?

[@TAZattitude]

That would be High Teck 77453 (buff color)

[@zardportugal]

First Class job.

[@TAZattitude]

Appreciate it!

[@jackww839]

Great work👍

[@TAZattitude]

Thanks Jesse

[@MatthewScott]

Put about 80 pai of air in it and it'll pop that dent. I've done it before.

[@JonHinton-uh7ng]

this should help me get the dent out of 92 zx600r tank

[@TAZattitude]

Or unless you can get another tank cheap. But a '92, I'm sure that's a hard one to find. And even if you do, then you have to worry about rust on the inside. The tank in the vid, is a very hard tank to find. Only made 2000-2003

[@JonHinton-uh7ng]

@@TAZattitude its very difficult. And from the kawasaki site they want 750$ for one. but i got a solution from my boss saying i can clean the tank and seal it and use the method you used with the bondo

[@TAZattitude]

Use everglass or Durabglass first, then finish with bondol

[@TriplicateTrey]

Forcing so much air into your filler with your mixing technique. Push, swirl, fold, push

[@scottf4249]

thank you

[@russellcrockford2519]

dodgy as.