Fuel Tank leaking, gutted :-(

When removing all of my secondary flies and shafts I noticed a film of something on the inside of one of the spoilers and on the radiator, was black and a bit greasy so I was thinking oil but in a weird place for oil and wasn't in the right sort of place to have happened as a result of my crash at Brands, so anyway by the time I finished it was too late to start the bike and check for a leak as I'd just put the kids to bed so I packed the bike away to come back to it later.

So next time I go back out there, I can see even more residue this time going all the way up the angled part under the spoiler to one of the drain bolts where it was obviously wet and it stinks of petrol, the first lot must have mixed with some oil residue and dirt or something to make it seem oily and wasn't a strong smell then.

I was hoping the drain bolt just needed tweaking or a rubber washer replacing or something but when I took the tank off to check I found just above the drain bolt a small circle where the tank material appears to be thinner and the petrol is basically seeping through that area.

Spoke to a plastic welders and it turns out the tank is not repairable as it's nylon based and cured under pressure or something, they said there's no adhesive or plastic they can adhere to it.

I can't believe it, all the cost and the work my friend put into getting the custom paint how I wanted it and issues we had with dodgy matt lacquers that were supposed to be the match for KTM matt etc and it's all wasted, apart fom using it as a template for redoing the paint job on another tank or some kind of modern art garden ornament.

Luckily I bought it as a spare tank before I had it painted so I still had my original to fit back on so I won't miss brands for now but I'm gutted, I was really hoping to get all my graphics done this year for the Cadwell Crashfest but might not have time or cash to sort it before then.

And I just missed another spare one for about £60 on ebay because of a massive project at work and being on conference calls day and night.

Just a thought, could you use a product like this?
http://www.kbs-coatings.com.au/kbs-tank-sealers

I dont think that would be suitable, im pretty sure when I was swapping fuel pumps from 06 to 07 tank that the inside of the tank had a plastic internal cell which was a clear off white colour, this held the fuel but was almost vacuumed to the inside wall of the tank.

might be clutching at straws but worth a look at this -

http://jbweld.net/products/water.php

would have to bench test it with some fuel in it as don't want it to get quickly worse and start pissing out fuel into the wrong place on a track day or something, leaving me and the track with a flaming mess to deal with.

what was the paint job? do you have a pic

Not quite sure where you are talking about.

Don't know what the thread number is but the URL will get you there:

viewtopic.php?f=1&t=10626&start=25

On the second page I've got some pictures of what I did. It's been fine for 18 months and is no worse than having an old fashioned fuel cock
screwed in.

Hope it helps.

PS I guess the thread is 10626 Doh

colour scheme don't look bad, and the paint job looks good too. bloody shame.