The old Vesco tank I had bought off eBay for the Baja Commander replica was in very good condition, but the color was not right.
I contemplated buying a brand new equivalent from Clarke (apparently, Clarke had bought Vesco's shapes back in the day), but even with paying over $200 I wasn't sure I would get the right color.
So I searched the internet for the right way to paint a plastic fuel tank. The results of my searches were not totally satisfactory. I did find procedures to paint plastic but none of them guaranteed that I could use the tank normally.
There were two challenges to overcome:
I had no idea what plastic the Vesco tank was made off but this did not seem to matter to my fore-bearers. So here is what I did.
Special materials:
Procedure:
In retrospect, I should have put the stickers under the clear coat. But there is always time to add a couple of layers of clear coat later.
I also did the front headlight shroud and the side panels while I was at it..
After 100 miles in the Mexican desert, the black marks on the side are wear from my pants. These came off nicely with 1200 wet paper. There is still plenty of lacquer left on the tank. Finished with polish and buffing. Very easy. I had the replace the stickers that were worn out.
The bike remained parked for 4 weeks after the race with 110 octane fuel in the tank, no sign of bubbling.
A great success but wasn't cheap or fast...
An important usage update:
After 8 weeks of keeping fuel inside the tank,... bubbles started to appear. Obviously, fuel vapors found their way through the liner and the plastic to the paint job. I popped the bubbles with a small pin and pressed them back flat. Since then I always empty the tank and leave it to air between rides. So in conclusion, it is a half success...
One year later:
After The paint is holding very well, no problems there. Inside however, the liner has come off the plastic walls. It is now a very hard shell replicating the shape of the tank, only a few millimeters smaller than the tank. Not good, but I will probably just leave it as is.
February 2015
In a Facebook thread about plastic tanks, Mr Preston Petty himself informed me that this tank is a "cross-linked polyethylene roto-molded plastic" item. There! I like to know what things are made off, this is great info.
2018
The paint is peeling off. That btank is good for trash. I learned my lesson :)