my 89 K100 rs had 11 (eleven) pin holes that I repaired with permatex epoxy. I am considering using an epoxy coating ( tank lining ). My thinking is that a lining would cut the chances of getting a leak while out on the road. The manufacturer ( Caswell ) says its good for aluminum tanks. I have never lined an aluminum tank. What do you think?

If the surface was prepared properly the permatex is very good. I have used it on 4 different tanks now and none have failed the oldest being 6 years since repair.

I have used JBWeld with good results, but indeed, good surface preparation is required.

maybe my question is misunderstood. my repair is good with no problems. what I am thinking about doing is coating the tank inside. the reason being that I repaired so many pin holes. any experience with this process on an aluminum tank would be appreciated. thanx.

There would be no reason why a tank liner would cause any problems on an aluminum tank esp if the liner manufacturer says it would work. I would advise keeping the literture that comes with it plus any email correspondence so you have a chance of redress if there product fails. Although they would probably claim incorrect preparation.

The worst case scenario if it went wrong would be a leak in the tank at one of your repairs, or the lining coming off and clogging up one of the 2 filters in there....

The other option of course would be to flush the tank out totally so there is no vapor left inside and get your holes welded... yes it's a step backward but it wouldn't require a lining... The final question is have you identified what caused the holes in the first place?

i believe it was moisture when p/o left the bike sit for an extended period. the paint blistered at the lowest point of the tank (11 places). under every blister a pin hole. it is repaired. my concern is that the tank wall may be thin in this entire area. what do you think?