Well, that sucked. I got home at 2:30 from work and immediately started trying to fix the XS before I had to leave. I discovered that the pin hole leaks in the gas tank were still wicking out through the gas tank sealer I had put on. This would never have happened if I just did a leak test before any off this. I assumed it was fine. I'm dumb.
So I got home, put some back-up JB Weld on, and ground down the engine bracket bolts that were still rubbing the tank. I got everything else in order and left at 4 to go to Grass Valley. It was one of the windiest days in quite some time. I made it 40 miles, just before the bridge to Isleton, when I stopped for gas.
I looked under the tank and saw that the tank had shaken around and STILL rubbed the bolts I ground down. This had completely torn apart the JB Weld and Gas Tank sealer. I touched the slow drip and it became a gusher. I had to stick my finger into the stream and push the bike to the side. I sat there, with my finger stopping the pee stream, and tried to figure out a solution. I finally ended up taking the tank off, turned it upside down, and used some electrical and duct tape to try to use pressure to stop the leak.
I went as fast as the XS would let me go and charged home 40 miles. As I pulled into the house, the tape looked good still and was holding. I went inside, kissed my wife, and went back outside to see that the tape had dissolved into a goo puddle.
I need to do a bit of modification to completely clear the bolts. Our new electrical panel gets here May 19, which means I can finally hook my welder up and fix it. Yes, I am completely removing any fumes in the tank first.