Dual tank? Modifications

[old_skool]

I'll be following this one, I've been contemplating the same thing with a spare leaky tank I have, what kind of welder will you be using to weld the tank back together, do you have access to all the sheet metal fab equipment?

 

[ValorSolo]

I have a wire-feed and two arc welders. I'll be using the wire-feed on the tank.
Proper cutting should eliminate the need for anything other than a hammer to shape the metal.
It'll also make the welding and smoothing/sanding less of a chore.
I sure hope I can locate my nibbler, using hand snips will be brutal for this much cutting.
Other than a hammer, anvil and nibbler, I'll be using a side grinder to dress the edges and smooth the welds.
If I were building a tank from scratch, I'd most like want a decent folding tool, seamer and notching tool.

 

[old_skool]

post a pick of your nibbler when you can

 

[ValorSolo]

Mine is actually pneumatic. I burnt up too many of the electric ones .
And the air nibbler will cut stuff that the electric can't come close to handling.

I haven't seen mine since I quit working on the road, haven't needed it, either.
I'm hoping my brother borrowed it or it's in my old gang box.

 

[old_skool]

I believe this is a metal nibbler. Look may vary. Might even be electric.

DP

Gotcha. I had an air hammer with a bit that worked the same way, I wouldn't mind getting a hand operated one for thin sheet metal small work.

 

[ValorSolo]

DeWalt has a 18-volt cordless nibbler that works pretty good.

From Home Depot:
DEWALT 18-Volt Cordless 18 Gauge Swivel Head and Shear

 

[MisterCinders]

If you are splitting the tank into three parts, you might hunt down a later tank that had a sending unit. I think the 1979 GS750 (1980 maybe?) had the same tank but with a fuel gauge sending unit. If so, grab one of those off ebay and swap that side from the old tank when you reassemble your Voltron tank.

 

[ValorSolo]

I have a sender from a GSX750. I may have to bend the float arm to adjust it, but it should work.

 

[ValorSolo]

Still waiting on a replacement tank. But I did get a sender from a GSX750.
I'm also looking to buy a tach that has a fuel gauge in the bottom.
Waiting for another tank before cutting this one is not easy.
I'm ready to get a tank, any tank, on my bike and ride.
And it looks like I could have this one ready before a replacement will arrive.

 

[ValorSolo]

Well I couldn't wait any longer. I cut open my tank yesterday.
After getting it apart, I was able to get to the dents with a hammer.
They smoothed out just fine, with little effort.

I was also able to find a good placement for the sender and adjust it properly.
I'll still have to weld in some mounting nuts and make a gasket.

I've scratch the second petcock, simply because I only have one petcock on hand.
It's really not needed, so no need to spend the time and money to get another one.

I'll post some pictures after I clean all the pieces and get them laid out.

 

[ValorSolo]

I guess I got away from this project for a while. Been busy with other things.
This tank popped into my mind this morning and I put a little more thought into it.
Instead of cutting new metal, shaping, welding, grinding, checking for leaks, filling, sealing,
sanding and finally painting, why not just use fiberglass?
I don't have a lot of fiberglassing experience, but I've done a little. Not really much to it.
Much easier than all that is involved with welding, with hopefully better results.

Any suggestions on material to use? Epoxy resin? Type of cloth?
Or should I go about with my original plans and just weld it?

 

[1948man]

Did you ever pursue this?