Topic: Tank Dent Removal on Honda SL350K0

[pjandrew99]

My CB750K1 tank had a few dents that I was able to remove with the PDR rods. Came out great.
This SL350 tank is a different story. The dent is on the left side which provides very little access for the PDR rods.
I will be repainting the tank if I can get this dent out enough to use a reasonable amount of filler and skim coat.
What I have tried so far:
1- High heat than cold. No good
2- Inner tube/air. No good
3- Hot melt PDR kit. Marginal at best
4- Harbor Freight Stud Welder. Terrible and put hole in the tank.
My latest attempt is soldering a bolt on to the dent with 30/70 solder. One pull and it came right off.
I'm pretty careful about prep with all these methods. I can't get anything to work.
I saw someone on a forum suggest silver solder. Before I throw more money into this tank I'm hoping to get some direction.
Maybe this is my excuse to buy a welder? I'm thinking that is my only option. Either welding a bolt on to the dent or opening up the tank, pushing the dent out and sealing the tank back up. I have no welding skills so that could be a disaster.
Thanks!

[calj737]

Use a hole saw and drill an access hole in the bottom of the tank. Pop the dent out with a PDR rod. Weld in a patch over the hole, grind it smooth, repaint the tank. Done.

[Oddjob]

No offense Calj but that sounds like a recipe for disaster. He has NO welding skills. Cutting a hole in the bottom of the tank means petrol sitting on the weld, any pinprick hole will mean a leak. Cutting a hole ABOVE the dent is a much better idea IF you really want to cut a hole at all.

Take it to someone who can weld, get them to weld a rod or 2 onto the dent and pull the dent out with some sort of slide hammer is my advice.

[calj737]

He can braze the repair in, or have it welded in. Any half competent welder can repair a hole and a patch. There’s more likelihood of his original tank having pinholes and leaking than a weld repair.

I’ve repaired dozens of tanks by very similar methods. Takes about 5’ to weld it up and less to smoothe out the weld if you’re decent.  A hole “above” the dent won’t provide the leverage needed to push the dent out; that’s why you put the hole in the bottom.

[pjandrew99]

Welding seems like the way to go. Appreciate the help!

[BenelliSEI]

Based on my recent experience, take it to a good PDR shop. They can work miracles!