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some years back I bondo'd a dented tank and repainted it. First I stripped all the parts off (cap, petcock, and since it was an old KZ tank it had screw on 'Kawasaki' badges). Rinsed it out thoroughly with water, then sandblasted it, in and out. Remember that sandblasting creates lots of static electricity so THOROUGHLY rinse all gasoline and fumes out of it. Then I rinsed it thoroughly again to get all that glass bead out. Then I bondo'd the dent and the area where the badges were originally mounted (I was eliminating the badges). Then lots of sanding, cleaning, primering, sanding, cleaning, painting, sanding, cleaning, painting, etc, etc. I'm not that great of a painter and it was only a rattle can job, but I think the prep job was pretty good. I think you should do something along these lines. Thoroughly clean it, blast it, fix it, then probably blast it again and clean it again. You'll probably have to grind the welds too so you'll have some prep work to do there too.
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Quote from a Kaw mechanic (my dad)
"Great idea, buy your kid a ninja for his last birthday."
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