Surface rust on underside of tank, around petcock - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 3 (permalink) Old 04-10-2010, 08:15 PM Thread Starter
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Question Surface rust on underside of tank, around petcock

I was out looking at my bike just now and discovered that the paint on the underside of the tank around the petcock is brittle and has chipped off about 1/2 an inch to the rear, maybe an inch to the front of the petcock and just a bit wider than the petcock to each side. Fortunately it is just surface rust at this point.

I think the best course of action is to drain the tank, remove it, and inspect the bottom of the tank to see if the problem is bigger than the little piece I can see. It is not really visible unless I am laying on my back, looking up at the underside of the tank, so I am not too concerned about color matching or having a perfectly smooth unblemished finish. I just want to protect the metal tank and keep it from rusting. I figure I can use a 2" or 3" rotary wire brush on a 3/8 drill and/or some wet and dry sandpaper to clean the rust off and remove any further loose paint I find there.

Do I want to use any Navel Jelly on it before priming and painting?
I don't think so, just sand and wipe off with some paint thinner or wash and wipe, before painting?

What kind of primer and paint do I want to use, to avoid problems with gas washing it off or weakening the bond?


1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15

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post #2 of 3 (permalink) Old 04-10-2010, 09:30 PM
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All your prep work sounds right...although I would Tape off the petcock with a sandwich bag and masking tape.

What kind of primer and paint do I want to use, to avoid problems with gas washing it off or weakening the bond?
I am using Krylon paints to paint my tins... spilled gas onto my clear coat and didn't get the wash, (and it was very fresh paint).
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post #3 of 3 (permalink) Old 04-10-2010, 11:35 PM
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Don't paint the area where the o-ring seals against the tank. Gas will dissolve the paint, and the seal will leak. I would sand the area, making sure to clean the area where the o-ring goes, then use a small brush to paint around the petcock. You won't need to mask anything, unless you have a really large area to paint, just cut in around the petcock with the brush. I noticed that the bottom of my tank is not completely painted, looks like they just hit it with overspray. No rust here in AZ. Jerry.

I am a motorcyclist, NOT a biker.

1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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