[Convince Me]

Update: This morning, I'll be ordering a new fuel filter w/ o-ring, and a new fuel sock. These are not expensive, and it sure can't hurt to replace the 17-year-old originals.

I'm not replacing the fuel pump at this time, ...or should I? Hmmmmmm. What do you guys think?

You took this one out.....it looks new to me?

 

[JLR]

Dyna, Schmidy mentioned a while back that he changes the pressure regulator too.

 

[DynaOSix]

OK, I get it fellas, it's a stupid idea.
So:
NO, on a new fuel pump strainer (it's not ripped or gunky)
NO on a new fuel pump (although it's been sitting dry for years), so, who knows
YES on a new fuel filter (it's turned black with gunk)

 

[DynaOSix]

Today, I applied a thin coat of spot putty to the dent repair. I do not have any spreaders, so I used a thick card

.

 

[DynaOSix]

Update: I ordered the OEM color paint and clear coat. I am using Colorite's aerosol cans. The clear coat will be their KK7 Urethane High Gloss gas resistant clear coat.

Still working on the dent.

Still need to order the speedometer - expensive.

 

[DynaOSix]

Update:
Still working on the dent. Now I'm applying filler primer – 600 wet sanding between coats. It's getting there, should look good when finished.

Spray on, wait for it to dry, wet sand…repeat

 

[anksbck]

I’m curious what type of gauge you went with that displays the fuel as well. Do you have a pic or a link that I could see?


Sent from my iPhone using Tapatalk

 

[DynaOSix]

I’m curious what type of gauge you went with that displays the fuel as well. Do you have a pic or a link that I could see?


Sent from my iPhone using Tapatalk

Combination Digital Speedometer/Analog Tachometer | Harley-Davidson USA

Find Combination Digital Speedometer/Analog Tachometer at Harley-Davidson.com. Free shipping on orders $50+ and free returns.

www.harley-davidson.com

 

[DynaOSix]

This is how the dented side of the tank repair turned out:

 

[DynaOSix]

Update:

Today I wet sanded the tank with 800 grit sandpaper, then put three more coats of primer on it. Last, I'll wet sand with 1000 ultra fine grit before painting

 

[Wooden Rat]

I've heard about filling the tank with water and putting it in freezer for a couple days. It will expand and push dents out. I know it's too late now for that

 

[DynaOSix]

Update: I ordered a can of this clear instead, seems much easier to use. I'll clear coat the tank with this:

Amazon.com: Spray Max 2K High Gloss Finish Clear Coat Spray Paint | Car Parts and Repair Refinishing Clear Coat for Permanent Sealing of Coated Surfaces | 3680061 : Automotive

Buy Spray Max 2K High Gloss Finish Clear Coat Spray Paint | Car Parts and Repair Refinishing Clear Coat for Permanent Sealing of Coated Surfaces | 3680061: Spray Paint - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

 

[I'm Rich]

$25 a can.

I guess I haven't bought spray paint in a while. But if it's good stuff and lays down nicely, then it's worth it.

 

[DynaOSix]

We will find out soon enough

 

[DynaOSix]

Today the tank was painted. The entire tank turned out well. The dent repair looks flawless – gloss black paint is unforgiving and will show every flaw in the bodywork. I'll let the paint cure for 72 hours, then reassemble the tank.

 

[DynaOSix]

Today I'll start reassembling the fuel tank. For starters, a new check valve with fuel line is installed.

 

[DynaOSix]

Installed a new in tank fuel filter, you can see the old one, yuck (probably the bike's original one). Installed the fuel level sender and fuel pump assembly into the tank. Using new gasket and sealing screws, I started the screws on the tank's top cover. I'll torque them to spec after a break.

 

[SCHMIDTY]

All is looking good. Make sure to fully seat the filter and regulator, they have a tendency to leak after the bonnet is installed to the tank.

 

[DynaOSix]

The filter is seated well - it fought me a little.

The tank is bolted on, all connections hooked up. Now to go get some gas and see if this thing will start and run.

 

[DynaOSix]

Update: It fired right up, seems to run just fine, idles nicely. There are a few things to adjust before the road test.