Gas Tank Modification Archives | Page 2 of 2 | The Shop Blog

’80 KZ750 | gas tank

May 3, 2015

by Matt with No Comment Fabrication Gas Tank Modification Welding

: I wanted to dish out the sides of the tank, so I cut out the shape I needed.

: This gave me great access to the inside of the tank. This was the best time to clean out the rust and hammer and dolly the dents.

: After all the cleanup work was done I started to make the panels that would fill in the sides.

: Panel by panel, the tank is filling in.

: I was making one panel at at time, working from side to side to make sure the tank was coming out symmetrical.

: All panels on both sides are tacked in at this point. I just need to weld them in fully.

: All burned in!!! Just a little clean up, pressure test, and time to start getting ready for paint.

So I started out with the original gas tank, and exploded it into a steel beach ball (hopefully the first and last time I do that). I did want to use the tank however. Lucky my local motorcycle salvage yard, Southwest Motorcycles, had what I needed!

I then started out with another stock KZ750 tank. From there I had a little work to do. The new used tank had some dents as well as some rust to address.

stunt tank | 636 flat top

February 23, 2015

by Matt with No Comment Fabrication Gas Tank Modification Welding

: I started out by making some rough marks where I wanted to cut. At this point I’m just trying to get a idea of where the lip is going to be.

: I made a rough cut with the plasma cutter. I cut around the gas cap mount in order to reuse it on another tank.

: I cut out a shape I thought would work for the lip and added it to the back of the tank. Then I massaged the opening to fit. I then added the new gas fill opening in a new location. All that is left is the top.

: I then cut out the top of the tank. A little shaping on the slip roll and it dropped right in. This is the tank all burned in and pressure tested for leaks.

This is a 05-06 Kawasaki 636 tank I had hanging around the shop. I bought the bike for parts. I used the majority of the parts on a KZ650 build. The 636 tank was not going to be used, so I figured mod it out and sell it.

King Sportster Tank | Chop & Mount

January 15, 2015

by Matt with No Comment Fabrication Gas Tank Modification Welding

: Since I’m going to be making the tunnel deeper, I started by cutting out the bottom of the tank.

: Fresh steel!!

: I had a donor Harley tank lying around, I decided to use it’s deeper tunnel.

: I mated the used tunnel and the fresh steel to make the bottom of the tank.

: I reused the petcock mount from the original bottom.

: Time to weld in the new tunnel.

: Looking good!

: I reinforced the mounting points to battle the engine vibrations.

: Rear reinforcemented

: Making the front tank mount. Just a piece of half inch stock drilled and taped.

: I ran the mount through the frame and burned it in.

: Preasure checking. Not as manny holes as I though there would be. I chased down all the pin holes for a good seal.

I found this bitchin little tank on Craigslist. It sits a little to high. So I decided to chop it! I kept the chrome in mind while making my adjustments, I don’t know if I will use it later for the finish. I also reinforced the mounting points to battle that Harley Davidson shake.

The Shop Blog | Swerve Customs

Posts in category: Gas Tank Modification

’80 KZ750 | gas tank

stunt tank | 636 flat top

King Sportster Tank | Chop & Mount