Replacing/Refurbishing/Mending 1983 Suzuki DR125S Fuel Tank

[WilfRegius]

I took my bike out for a late afternoon sunny ride on Sunday and stopped for a break after around 45 minutes. Upon kicking her over to head back on to the road I looked down to see a stream of petrol coming out of the bottom side of the tank.

On close inspection I see there is an approx. 3mm hole where a flake of rust has popped off and another hole has opened where I have rubbed my fingers along the painted over rust.

I only bought the bike and did my CBT around 1 month ago but don't want this to be a large hurdle to getting back on the road. My intention is to mend the tank myself as a temporary measure until I can find another original tank which seem to be rocking horse expletive/hens teeth. I have found 3 different ones up for sale in the states but it's outrageous postage for a fuel tank and none have been in great condition.

I have had some advice on sanding back any rusty parts followed by a treatment to stop any further rust followed by chemical metal paste patch up followed by a resin reseal of the inside of the tank. Frost was the brand recommended. I would like to do this myself but may take me some time as have done nothing of this sort before combined with busy work schedule.

Any advice on the mend/refurb?
Anyone know where I could get a half decent original replacement tank?
Would it be possible to put a fuel tank from a different model on my bike? (for example a GS125 that were pretty much the same bike mechanically and spares seem to be much more readily available.)

Many thanks
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In search of a 1982/3/4 Suzuki DR125S Fuel Tank

[Vincent]

Have you seen one in The States? If so, how much did they want to charge you for shipping?

DIY tank repairs can be a bitch...... and sometimes the tank needs the whole side cutting out and replacing. Proper tank repairers would split it in two to make sure the inside surface is cleaned up right and sound enough to work with.
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Space Is Deep

[WilfRegius]

I found a half decent one from the states but they wanted $71.50 just for the shipping plus I would have to pay the tax when it got here.

I got quoted £240+ VAT for a full professional cut open as you described. Just can't justify it at the moment when I only spent £800 on the bike itself.
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In search of a 1982/3/4 Suzuki DR125S Fuel Tank