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DIY tank dent removal

This is a discussion on DIY tank dent removal within the General Ninja 650R forums, part of the Kawasaki Ninja 650R category; I have a dent in my tank and am looking at ways to get it mostly out without spending a lot of money. The dent ...

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  • 1 Post By steveinsandiego

Thread: DIY tank dent removal

  1. #1
    Up-And Comer Tailgun's Avatar
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    DIY tank dent removal

    I have a dent in my tank and am looking at ways to get it mostly out without spending a lot of money. The dent is about baseball sized and 3/4 inch deep. There are no creases, so it should be the best canidate for removal without welding. I tried the heating and cooling method without any success. I'm just looking to get it good enough that I can skim sime filler over it and repaint.

    Does anyone have any recomendations?

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  3. #2
    Up-And Comer CytokineStorm's Avatar
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    Try the suction cup tool? Ding King is popular one. I know they make a smaller one that would be better since there is less area on the tank.
    I seen a video where he heats the heats with a sol panel reflector, just to soften the paint mainly I'm sure, then sticks a metal rod in with a rubber end wrapped in cloth to keep from scratching anything and pushed it out.
    I have one too, I just don't know if it's worth fixing since I may be painting in the off season(winter)

    Other than that I doubt there's a magic fix. The weld/hammer pull technique is great. If you do it, just be sure to empty your gas tank in-case and if you take it somewhere remind them, just in-case.

  4. #3
    Site Elder pt377's Avatar
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    I hear if you hold dry ice on the center for a few minutes the pull back in a quick smooth motion it should pop right out. Let me know if it works LOL
    '06 650R Drag bars & Eliminator kit
    remember "Road Rash" on SEGA? Ill just carry a Chain

  5. #4
    Supreme Being steveinsandiego's Avatar
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    i've never seen evidence to verify this technique, but i heard that if you blow hard enuff into the exhaust pipe the dent'll come out.............
    djrussell likes this.

  6. #5
    Site Elder barbos's Avatar
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    I had a dent in my tank, caused by me headbutting it during a crash. It did crack the paint, but I couldn't seem to find anyone that was willing to work with gas tanks. The ones that would, wouldn't touch it for less than $250-300, and that was just for the dent, no painting. New tank was only a bit more, so I ended up just replacing it.


  7. #6
    Up-And Comer CytokineStorm's Avatar
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    I have heard of sealing the tank the best you can then pushing in compressed air. I don't know how many PSI it would be close to needing. You also chance deforming other areas of the tank if the dent isn't the weakest point.

  8. #7
    Up-And Comer Tailgun's Avatar
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    Well I tried several methods with no success. I went ahead and had my local shop pull the dent and repaint the tank.

  9. #8
    Supreme Being Smash's Avatar
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    What did it cost you?
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  10. #9
    Up-And Comer Tailgun's Avatar
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    I found a local shop that would pull the dent, and repaint including clear coat for $300

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