Hey folks, just joined - my D2 (5U) has been sitting for a couple of years because of a rusted out Pony Tank. When I say rusted out, I mean it has no smooth surfaces on the inside and when I put rust remover in it, the tank turned into a colander (12 holes and counting). Finding a replacement tank has proven impossible up to now and the prospective replacements I've gotten - 1 go-cart plastic tank and a Yamahopper moped tank won't fit into the ridiculously cramped space under the hood. I've considered using a boat tank and mounting it on the fender, but since the carb is so cranky from getting cruddy gas, I'm afraid the bulb siphon will flood it immediately.

Are there any replacement tanks you folks found that will do the job and/or fit under the hood? Or someone who is willing to make a replacement?

if it only pin holes you can use a fuel tank sealer such as redcote. there is several to choose from.

or if you or a friend has a sheet metal bender it not difficult to bend up a new tank just remember it will need to be in 2 pieces no bender can do a one piece tank. and then weld or solder it together

also try a wanted add on the sale section of the forum never know who has what laying around.

You might try a plastic coolant overflow tank from a modern car. There should be tons of different sizes or dimensions in the junkyard.

I have an extra u series tank in good shape. I can get pictures if you're interested

I would think a two-piece steel blank could be made for these tanks and then stamp them out and weld them together, or with all the CNC machines available to make a die, it could be easily done, look how aluminum billet rims are made.

Definitely! Please do. [In response to the extra tank pictures. I guess I replied to the wrong post.]

After rust removal, redcote was the next step but each rust removal pass created more holes and the inside was still totally chunky. I've got some welding experience but it is limited to lumber racks and theatrical light towers - all bar and plate stuff - nothing precision at all. I need some CNC-equipped friends.

The tank still has a wet residue from old gas in the bottom
If it was mine I would clean it and use it, I'm not a big fan of coating
I can't seem to load pictures but I'll try again

I fought rust and crud in my D4 pony tank for years and finally broke down and lined it with the red stuff about 10 years ago. Can't believe I didn't do it sooner. It still has a small inline filter in the line but it never picks up any dirt or rust.