I began looking into what's required of using Paddy's tank today. Of course, the petcock leaks! Others have exhaustively searched rebuild kits with little luck, and the petcocks are unobtanium (one on ebay that looks worse than mine)!
I drilled out the "rivets," which aren't rivets at all. Turns out they're bosses in the petcock's main body that, once the res/off/on plate is seated are then mushroomed to secure the plate. If I had it to do over again, I would have filed off the mushrooms and just popped off the plate. Thinking they were rivets, I also continued to increase the bit size wondering why the rivet heads wouldn't pop off. So, I may have drilled too wide in the petcock's body to allow me to tap it (hope not). At this point, I don't know if I should try to tap the bosses or file them flat and tap the petcock's body. Here's what I ended up with:
When I popped off the top plate, parts flew! Is this the correct order of assembly? I'm not sure if the fiber washer or the spring ring goes on immediately after the lever:
I think I'll reuse the four-hole gasket by flipping it over (in hopes of saving time before IT gets here). I understand this gasket can be ordered if it still leaks. Here's a pic TwoTired posted:
http://forums.sohc4.net/index.php?topic=34758.msg413245#msg413245Online parts diagrams show a washer (looks like fiber/nylon) between the tank's fuel screen and the rubber washer inside the petcock. The former was missing on my tank, and the latter is trashed:
I can't locate the petcock's rubber washer online, so I'm going to see if I can make/buy one.
On to the tank. Here are some shots. If it were yours, would you rinse it with Phosporic Prep and Etch? I've never done this before, so I don't know if this is too much rust or not. It is most prevalent in the final pic. I had to use my shrink ray and parachute in to get these pics!
Your ideas/opinions would be great!