Sylvie Willis
Building a motorcycle fuel tank can be a challenging task, but with the right tools, materials, and techniques, it is achievable. Whether you're a DIY enthusiast creating a custom tank for your bike or a professional fabricator producing one-off designs, there are several factors to consider. These include the style, capacity, and functionality of the tank, as well as the materials used, such as steel, aluminum, or fiberglass. The process may involve cutting, welding, grinding, and shaping the tank to the desired specifications, ensuring a proper fit and leak-proof construction.
| Characteristics | Values |
|---|---|
| Materials | Steel, aluminium, copper, fiberglass |
| Tools | Shrinker/stretch machine, planishing hammer, English wheel, air-powered die grinder, air sander, TIG welder |
| Design | Style, capacity, form, function |
| Process | Cutting, welding, smoothing, shaping, sealing |
| Parts | Filler cap, neck, petcocks, bungs, tunnel, mounts |
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Design and material
When it comes to the design of a motorcycle fuel tank, there are a few things to consider. Firstly, the style of the tank should either match the design lines of the bike or be made to your liking. The capacity of the tank is also an important factor to consider, as it depends on where the motorcycle will be ridden. The material and its thickness will play a large part in how the tank will be made. Common materials used include steel, aluminium, copper, fiberglass, and carbon fibre. The thickness of the material will determine the capacity of the tank and how well it holds together.
For a custom fuel tank, one may need to fabricate their own tank using materials such as 20 or 22-gauge mild steel sheets, or fiberglass with resin. If using steel, a planishing hammer can be used to shape and form specific areas, and an English wheel for final smoothing. A wooden "buck" can be created beforehand to help achieve the desired final shape. If using fiberglass, a mould will need to be created, and a vacuum technique can be used to save weight.
For those who are less keen on fabricating their own tank from scratch, there are aftermarket Build-Your-Own tank kits available, such as the one offered by Paughco. These kits come with shells, tunnels, mounts, and bungs, allowing for customization without the need for expert metalworking skills.
When it comes to assembling the tank, a few tools can be used. A shrinker/stretch machine can be used to manipulate the metal, and an air-powered die grinder can be used to cut along marked lines. An air sander can be used to remove any high spots, and welding techniques such as TIG welding can be employed to join the pieces together. To check for leaks, one can use compressed air or fill the tank with water to test for any visible leaks.
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Welding
When welding a motorcycle fuel tank, it is crucial to use appropriate safety equipment, including protective eyewear, gloves, and a respirator. It is also important to ensure that the work area is well-ventilated to prevent the inhalation of harmful fumes.
The first step in the welding process is to prepare the metal parts of the fuel tank by cleaning and grinding them to ensure a smooth and even surface. This helps to ensure a strong and secure weld. Once the parts are prepared, they can be clamped or tack welded into position to ensure accurate alignment during the welding process.
The type of welding technique used will depend on the material being welded and the equipment available. TIG welding, for example, is a common method for welding aluminium and steel fuel tanks. It involves using a tungsten electrode to fuse the metals together, creating a strong and reliable joint.
When welding the tank, it is important to work in small sections and alternate between welding areas to prevent warping. This involves welding a 1-inch section, then moving to another area to allow the previous section to cool before continuing. This process is repeated until the entire tank is welded together.
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Gas filler and switch housing
The gas filler and switch housing are important components of a motorcycle fuel tank. When building your own fuel tank, there are a few options for sourcing these parts. You can either purchase them separately or use parts from an existing tank.
If you're looking for a screw-type gas filler, you can find them for $36.95 each. For the gas filler neck, you can check online retailers like Amazon or motorcycle-superstore.co. You may also need to purchase a weld-in neck and filler, which can be found on websites like bungking.com or racepartsolutions.com.
If you're using parts from an existing tank, you'll need to carefully measure and cut the gas filler and switch housing from the old tank. Ensure that you have enough space on your new tank shell by making some crude markings before cutting. You may need to shave down the sides of the new tank shell for a proper fit.
When designing the gas filler location, consider the Frisco style, which involves placing the gas filler high on the top of the tank. To do this, cut a hole using a 2-inch hole saw, slide the gas filler into the tank, and weld it into place. Don't forget to finish weld the entire tank once all the structural work is done.
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Tank shape
The shape of your motorcycle fuel tank is a key consideration when building one. The style and design lines of the tank should ideally match the overall design of the motorcycle. The shape of the tank will also determine its capacity, which is an important factor to consider depending on where the motorcycle will be ridden.
There are several tools and techniques you can use to achieve your desired tank shape. If you're working with metal, a shrinker/stretch machine can help you manipulate the metal to your desired shape. A planishing hammer can also be used to shape and form very specific areas of the tank by delivering rapid tiny blows between two desired radiused steel heads. For final smoothing, an English wheel is a useful tool.
If you're working with fiberglass, you can use a forming bag and a mallet to form the panels of your tank. You can then finish off with a planishing hammer and various dollies to ensure a perfect fit to your wooden pattern.
For those who prefer a more straightforward approach, there are aftermarket Build-Your-Own tank kits available that come with shells and various tunnels, mounts, and bungs to build a custom tank without requiring expert metalworking skills.
It's important to consider the functionality of the tank shape as well. For example, the high tunnel of an old Harley-Davidson Hummer gas tank made it impractical to fill the tank with enough gas for longer rides. Modifying the shape of the tank to accommodate a larger fuel capacity can be a practical decision.
Additionally, the shape of the tank can impact the placement of other components such as the fuel cap, filler neck, and petcocks. Ensuring that these components are easily accessible and functional within the overall design of the tank is crucial.
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Leak testing
Before beginning the leak test, ensure that all the components of the fuel tank are securely installed, including the filler cap, neck, and petcocks. Any loose parts or connections could result in fuel leakage. It is also important to consider the material of your fuel tank, as different materials may require specific types of sealants or coatings to prevent leaks.
One common method for leak testing is to use compressed air. This involves filling the tank with compressed air and then using soapy water or a leak detection solution to check for any escaping air bubbles. Carefully examine all welded seams, connections, and joints for any signs of air bubbles, as these indicate a leak. This method is effective at detecting even small leaks and can help ensure the integrity of your fuel tank.
Another approach is to perform a water test. Fill the tank with water and observe for any visible leaks. While this method may not detect small leaks, it is a simple and initial check to perform before moving on to more advanced testing methods. After the water test, some people choose to send their tanks to a radiator shop for professional leak testing and coating.
For a more comprehensive test, you may consider filling the tank with fuel and letting it sit for an extended period, such as a few weeks. This method, suggested by a Honda Twins forum user, can provide a real-world simulation of how the tank will perform over time. However, this approach may require patience and the willingness to potentially waste fuel if leaks occur.
It is worth noting that some fuel types may be more suitable for leak testing than others. For example, E-85 fuel is suggested by a forum user as a potential option, as it is believed to be more indicative of the tank's performance with other fuels. Additionally, the use of sealants or coatings, such as epoxy sealer, is recommended by forum users to prevent leaks, especially for fiberglass tanks.
In conclusion, leak testing is a critical aspect of building a motorcycle fuel tank. By following these instructions and tips, you can ensure the safety and functionality of your handmade fuel tank. Remember to consider the unique characteristics of your tank, including its material and construction, when selecting the most appropriate leak testing methods and sealants.
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Frequently asked questions
You must first consider the design and purpose of the fuel tank. This includes the style, capacity, and functionality. The material and its thickness are also important factors, with steel, aluminium, and copper being common choices. Additionally, you should think about how the tank will be assembled, with welding being the most straightforward method.
A shrinker/stretch machine and a planishing hammer are commonly used to shape and form the metal. An English wheel is employed for final smoothing. A wooden form, often referred to as a "buck," is created to help achieve the desired final shape.
One challenge is ensuring a secure fit and alignment when joining tank sections. This can be tackled by using an air sander to remove high spots and then tacking and welding the sections together. Another challenge is checking for leaks. This can be done by using compressed air or filling the tank with water to identify any visible leaks.
Yes, some builders opt for a fiberglass fuel tank. This involves working with resin and addressing challenges like mounting the petcock and fuel cap. It is important to protect the foam and coat the inside of the tank with a sealer to prevent damage from fuel.
You can source parts from various online retailers and forums. Websites like bungking.com offer a range of parts needed for fuel tank construction, including weld-in bungs and filler necks. Additionally, eBay, local wrecking yards, and radiator shops can be good places to find donor tanks and necessary components.
