Z Performance

I really like the looks of these old Bultaco motorcycles just finished this one up, complete engine overhaul and wiring harness repair ready to go!

I ran into something new this week, don't know how common it is but I think I have found a cheap solution for anyone that has this problem. This is the story.
Started with the customer getting water in his fuel tank. Thinking it came from filling the tank from a gas can I drained the tank, refilled with fresh fuel and all's fine. It happened again and I got to thinking his cap seal must be bad and drained it again. Told him not to leave it out in the rain 'til I could find a fix.
Then it started to drip fuel under the bike so now something is leaking...
After some investigating I found the fuel to be coming from the fuel door overflow tube that runs down through the tank and out the bottom. Seems the overflow had become plugged and held water until it rusted through. When it rusted through it allowed rain water to flow through the rust holes (which were about 5" up from the bottom) into the tank. So now to repair it, it will have to be cut out of the tank and a new one welded in or buy a new tank.
That's when I decided to try something to save a little cash for the customer. It was a simple plan and wasn't going to do any damage to the tank. The following photos show what I did and it actually worked pretty well...