Tank rusted through. Repair or replace?

[Raydr]

A few years ago, I notice the inside was starting to rust so I took my tank to a local guy who worked on it and coated the insides with something. It seemed to do the job until late last year when I noticed a pool of fuel on the ground. It turns out that my tank actually rusted all the way through and there's a tiny pinpoint hole in the extreme end of the tank. The fuel is actually leaking from under the paint!

Anyway, I just took the tank off and set it aside to deal with it later.

Now it's later and I'm looking at my options. It seems that if I want a tank in decent condition, I need to spend around $500, which has been a bit of a tough pill to swallow since I'm seeing running GS500Fs for sale locally for $1800-$2400.

Due to some work stuff my time is a bit limited, so I realize my best option is just to exchange time for money and bite that bullet.

Before I go dropping $500 on eBay, any recommendations? Anyone think it's worth trying to get the tank repaired now that it's actually rusted through?

2004/2005 model.

[herennow]

Look up "POR15" , but if it's alrady been lined inside I'm not sure you can reline without getting the old stuff out. Not easy, needs some nasty stuff that can damage paint. I'd go and talk to the orignal liner. Should last more than a few years.....

[The Buddha]

I have a few that rusted too. Yea all were coated, some with por15 too. The design of a GS tank almost means you have to cut a big hole on the bottom, get into the crap pockets etc with sand paper first, then clean it out thoroughly, dry it prep it with that POR15 prep and dry and clean and all that and paint it with a brush. Then leave 1" around the hole you cut, tig weld it back and paint it through the filler and let it all cure and still keep a close close eye on it.
I dont know if I'd even trust an ebay tank, the design flaw in the GS tank prevents anything from being rust free in the crap pocket area.
Cool.
Buddha.

[aconti2]

After removing the rust from my GS500 tank you would have thought a porcupine exploded on the inside there were so many pinholes.

Used Casewell tank sealer and if the tank was any more airtight I think it would explode. I split the mixture into two parts and put two coats with fantastic results.

Buy it and follow the directions. Worst case you're out 60 bucks and best case you are good to go and don't need to source another tank.

[herennow]

Ive recently heard form some folks that the Caswells is preferable ot the POR 15 with modern fuels.....