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.
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.
