Caswell

[rf9rider]

Ssevy, How did you prepare the inside of your tank?

I`ve looked on Caswell website, but no mention of plastic tanks?

Need to do mine when it`s been resprayed.

[ssevy]

I honestly don't remember😳
The folks at Caswell are great if you call them.
They will tell you just what you need to do.

[rf9rider]

No worries, i`ll contact them

[Earthscape]

Yes, I pulled these and plugged the holes with a stopper. I installed a Pingel petcock, and left the mounting plate installed so that it would be covered by the seal and no fuel could sneak under the edge. Just be careful not to let the threads get the Caswell on them.

ssevy...
I'm nearly ready to get moving on this, finished my steering head bearings (piece of cake with the new Motion Pro steering head tools).  How exactly did you plug the low fuel sensor hole?  My plan was to get a replacement bolt of the same thread size and screw it in place of the sensor, then remove it, and after drying reinstall the sensor.  I have not been able to source the correct bolt locally to do this.  If I just put a stopper in there, the nylon threads will be coated with the Caswell.  I don't know if that's good or if it will make the sensor threads no longer fit.  I certainly don't want to damage the nylon threads by forcing something in there.  What did you do?

[Sin_Tiger]

Wipe some silicone sealant into the threads and them use a soft foam plug. That should clean out without doing any damage.

[ssevy]

I can't remember exactly, but I think I used a rubber stopper or cork? Sin's idea sounds like a great one too.

[ghulst]

This is a very interesting thread. My tank has swollen and I would like to get it back to being easily mountable. How long does it need to sit without fuel for it to get back to its original size? And how do you remove all the fuel from it from coating?

Oh, and if anyone is going through the lining process, care to take pics of what you do?

[ssevy]

How long does it need to sit without fuel for it to get back to its original size?
Mine sat about a month I think. You'll know it's ready when you put it back on the bike and everything lines up correctly again.

And how do you remove all the fuel from it from coating?
You drain it out the petcock, then remove all the hardware and let it air dry.

Oh, and if anyone is going through the lining process, care to take pics of what you do?
Sorry, no pictures of the Tiger tank.

[Earthscape]

Wipe some silicone sealant into the threads and them use a soft foam plug. That should clean out without doing any damage.

That's a good idea.  Perhaps some foam backer rod would do the trick...

[Sin_Tiger]

It'd probably do the job.

This might sound daft but I keep my old foam ear plugs for plugging holes