Fuel tank and side cover restoration

After doing tapered steering bearings, rebuilding the front brake, forks (including polishing), new grips/handlebars, etc. I finally broke down and took my fuel tank in to be stripped and repainted. I can't find a good before picture, but the paint was cracked and faded, chips in the tank, a couple dents, etc.

Tank stripped


Tank primed


I was sort of afraid to disassemble the side covers; I didn't want to crack anything, especially the emblems. I pulled the spring nuts off--the ones that hold the chrome piece on the painted part--by looping some dental floss under the four tabs and pulling them off. There's probably a tool for this. Chacal probably sells it.

To get the side cover emblems off, I heated the emblem and the back side of the side cover with a hair dryer, then pulled dental floss through the softened adhesive. It really helped to heat it up, and to wear some leather gloves so the floss didn't cut into my fingers.



The emblems aren't in great shape, but they're all in one piece. I'll need to restore them. I haven't a clue how I'm going to approach that yet. I'd like to have the plastichrome parts of the side covers rechromed too, but I haven't found a place to do that yet. I'm thinking about having them 3D scanned so I could make duplicates, since 3D printers are getting more common. We have one at work.

Next I cleaned up the side covers by picking at the adhesive and rubbing it with mineral spirits.



Tomorrow I can pick up the tank and side cover pieces from the paint shop. I'm pretty excited about this. There's no way I was going to paint this myself and have it look decent. I have parts on the way (thanks, Chacal) to rebuild the petcock and gas cap. I'll post some pictures of the new tank when I get it.

 

thanks for the tip on emblem removal I just painted my tank. did you cover the petcock hole? you dont want paint where the petcock goes.

 

I have contemplated this very thing. Currently I am thinking that I will use gold leaf (this is for an XJ550 SECA) and then finishing them off with clear coat. Not sure how feasible that will be, but I'll look to see if anybody else has done so when the time comes.