PDR Repairs / Articles

Harley Davidson Motorcycle Tank – Paintless Dent Repair Tutorial

Motorcycle Paintless Dent Repair / Removal Training Tutorial (Basic)

Well if you follow my blogs, I try to make things as interesting as possible. I stay pretty busy between running my two companies, training, finding time to post and edit videos. In case you were wondering, I do my own video editing myself. I believe you really have to know a lot about a little. And so I try.

Now about this Harley Davidson (Fat Boy) gas tank dent removal. It’s actually a warm up from what’s is to come. I will have the full version of this on AutoLecture.com. I will be releasing some DVDs shortly regarding my line board, basic training and other interesting things you PDR techs like. By the way, if you have any suggestions on what type of dents to do, please comment. I’ll do my best and try to fulfill your requests regarding PDR.


About the dent. This Harley tank was very challenging. One thing I did not mention was that the frame holding the tank was not bolted. I had one of my other techs holding the frame and he’s 6’5″ 260lb and it was still moving while I was pushing! I should have filmed that. That might have been even more interesting. So. I used a Ultra Dent Tools 24″ double bend soft tip. Used a semi sharp knock down and some patience.

Working on Harley tanks can be very difficult because of the gage of the steel. At times, I could not find my tip when pushing. The metal had very little flex to indicate where the tip of my tool was. I turned by line board way out to make the lines smaller so I can see the slightest pinch when I pushed. Still it was very difficult to identify. For beginners, I don’t recommend doing gas tanks right off the bat. Get good at reading your board and mastering precise tool tip location. That way you will have less doubt where your tool tip is at. Tanks like these can hurt your confidence or ego in a hurry!

If you are working in a cold environment, it might be a good idea to heat up the area really warm. The clear coat will less likely spider or crack on you and not to mention it helps with flexibility for the paint and metal. If you are not around any electricity, use a small pocket torch and wave near the surface of the dent. NOT TOO CLOSE! Glue pulling is not an option here. One thing, the clear coat is not as strong. Especially with a painted pinstripe going across the dent. Another reason, the dent was too deep to pull.

The repair took just about over one hour and 45 minutes. Cost was $260.

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