Hawk Gas Tank Leak Repair

Torgo · 12-11-2017, 10:14 PM

I’m just posting this for reference in case someone else runs into the same thing. My 2015 Hawk developed a gas leak several months ago. It happened around 2200 miles. I’ve done another 700 miles since without any problems, so I’m getting around to posting a couple of pictures I took of the repair since it seems to be holding up OK.

I started to notice a stronger than usual gasoline smell and discovered that it was leaking from the weld at the bottom of the gas tank and the fuel selector.

It was a welding defect - I’m guessing that enough rattling final worked open the joint, and it started to leak enough to be noticeable.

First pic shows the original bead and factory paint. Clearly, it’s not the best bead ever laid down – at least it’s wasn’t structural. I didn’t take a picture after I brazed it, but the joint wasn’t closed, and the disconnect went all the way through.

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Second one shows the materials required. The plumbers abrasive cloth worked good – brazed it up nice and easy around the selector (just like a copper pipe) and I expanded it out around the base to give the JB Weld a good area of contact.

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Third shows how the epoxy set up, and the fourth was taken after a quick coat of paint to cover up the repair, and the remaining exposed, braised areas.

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Wasn’t hard, just took some time to take off the gas tank and wait for the epoxy and paint to dry.

12-11-2017, 10:14 PM	#1
Torgo Join Date: Oct 2015 Location: Texas Posts: 93	Hawk Gas Tank Leak Repair I’m just posting this for reference in case someone else runs into the same thing. My 2015 Hawk developed a gas leak several months ago. It happened around 2200 miles. I’ve done another 700 miles since without any problems, so I’m getting around to posting a couple of pictures I took of the repair since it seems to be holding up OK. I started to notice a stronger than usual gasoline smell and discovered that it was leaking from the weld at the bottom of the gas tank and the fuel selector. It was a welding defect - I’m guessing that enough rattling final worked open the joint, and it started to leak enough to be noticeable. First pic shows the original bead and factory paint. Clearly, it’s not the best bead ever laid down – at least it’s wasn’t structural. I didn’t take a picture after I brazed it, but the joint wasn’t closed, and the disconnect went all the way through. Second one shows the materials required. The plumbers abrasive cloth worked good – brazed it up nice and easy around the selector (just like a copper pipe) and I expanded it out around the base to give the JB Weld a good area of contact. Third shows how the epoxy set up, and the fourth was taken after a quick coat of paint to cover up the repair, and the remaining exposed, braised areas. Wasn’t hard, just took some time to take off the gas tank and wait for the epoxy and paint to dry.
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