Regan Brown
Fabricating a motorcycle fuel tank is a challenging task that requires careful planning and execution. The process involves designing the tank to match the style and capacity requirements of the motorcycle, selecting the appropriate materials and thicknesses, and determining how the tank will be assembled. Several factors must be considered, such as the type of welding process to use and the number of welds needed. Additionally, the fuel tank's tunnel, mounting, and petcock bung need to be configured. While fabricating a motorcycle fuel tank can be complex, it is possible to create a unique and customised tank with careful measurements, cutting, welding, and testing for leaks.
| Characteristics | Values |
|---|---|
| Materials | Steel, aluminium, copper, fiberglass |
| Thickness | 18g, 20g, 22 gauge |
| Tools | Planishing hammer, metalworking tools, air-powered die grinder, air sander, TIG welding equipment, forming bag, mallet, dollies |
| Design | Style, capacity, form, function |
| Process | Welding, cutting, grinding, sanding, TIG welding, measuring, assembling, gluing |
| Kits | Paughco Build-Your-Own tank kits |
| Testing | Water testing, radiator shop testing, sealing |
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What You'll Learn
Choosing the material and thickness
The choice of material and thickness for a motorcycle fuel tank depends on several factors, including the desired style, capacity, and functionality. Common materials used for fabricating motorcycle fuel tanks include steel, aluminium, and copper.
When it comes to thickness, it is important to consider the welding process and the overall weight of the tank. Thicker materials, like 18-gauge steel, will provide more strength and durability but will also increase the weight of the tank. On the other hand, thinner materials, like 20-gauge or 22-gauge steel, will reduce weight, which is advantageous for racing or track days. However, thinner materials may require more careful handling during welding to avoid distortion.
For aluminium tanks, gas welding may not be a suitable option due to the potential for distortion. In this case, aluminium brazing or TIG welding could be considered as alternative joining methods. The use of aluminium also requires careful consideration of the fuel type, as some fuels may react with the aluminium and cause leaks.
Another option for fuel tank material is fiberglass, which offers the advantage of being lightweight and customizable. However, the choice of resin and sealant is critical to ensure compatibility with the fuel and to prevent leaks. Epoxy sealers are often recommended for fiberglass tanks to ensure a strong and durable seal.
Ultimately, the choice of material and thickness depends on the specific requirements of the motorcycle and the builder's preferences. It is important to consider the trade-offs between weight, strength, durability, and ease of fabrication when selecting the appropriate material and thickness for a motorcycle fuel tank.
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Designing the tank
Designing a motorcycle fuel tank involves several considerations, from style and capacity to material choice and thickness. Here is a step-by-step guide to designing a motorcycle fuel tank:
Step 1: Define the Purpose and Style
Start by considering the purpose of the fuel tank. Is it for a specific type of motorcycle or riding style? The intended use will influence the design and capacity requirements. Think about the style you want to achieve. Do you want the tank to match the design lines of your motorcycle, or prioritize function over form?
Step 2: Choose the Material and Thickness
The material and its thickness are critical factors in the fabrication process. Common materials for fuel tanks include steel, aluminum, and copper. Consider the advantages and disadvantages of each material, such as weight, durability, and ease of welding. For example, 18-gauge mild steel might be too heavy, so you may opt for 20-gauge or 22-gauge steel instead.
Step 3: Determine the Fabrication Method
Decide on the fabrication method, such as welding, which is a common and straightforward process. However, keep in mind that minimizing welds can simplify the process and reduce potential distortion. Consider the tools and techniques you will use to shape the material, such as metal forming by hand, using a forming bag and a mallet, or power tools like an air-powered die grinder.
Step 4: Create a Template
Create a template or pattern to work from. You can sketch the side and top profiles of the tank, ensuring they fit the frame of your motorcycle. Use these profiles to determine the overall length and shape of the tank. You can also create a buck from plywood to shape your original tank design, adding ribs or segments to aid in creating the desired shape.
Step 5: Plan the Components
Plan the components you will need, such as the filler cap and neck, gas filler, switch housing, and petcock bungs. Consider the placement of these components and how they will be attached or welded to the tank. Think about the tunnel of the tank and whether you want to include features like a high tunnel for a specific look.
By following these steps, you can design a motorcycle fuel tank that meets your functional and aesthetic requirements. The design process is crucial to ensure the tank is safe, secure, and compatible with your motorcycle.
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Cutting and shaping the shell
The first step in fabricating a fuel tank for a motorcycle is to decide on the design and material. The material you choose, such as steel, aluminium, or copper, will determine the fabrication process, particularly the welding method.
The next step is to cut and shape the shell of the fuel tank. This involves measuring and marking the desired size and shape on the shell, followed by carefully cutting along the marked lines. If you're working with a pre-made shell, this step will involve modifying it to fit your desired design. You may need to narrow, trim, or shave down the shell to achieve the required shape and size.
When cutting the shell, it's important to use the appropriate tools for the material. For metal shells, an air-powered die grinder or a similar tool can be used to make precise cuts. If you're working with a fibreglass shell, you may need to use different cutting tools or methods.
After cutting, the shell's edges may need to be smoothed or shaved to ensure a flush fit when the two halves are joined. This can be done with an air sander or similar tool, carefully removing any high spots or imperfections until the halves fit together perfectly.
Before joining the halves, it's crucial to check the alignment and ensure the shell is straight and true. This step ensures that the final fuel tank will be structurally sound and not leak. Any discrepancies or high spots should be carefully adjusted until the shell halves align perfectly.
Once the shell is cut, shaped, and aligned, it can be temporarily held together using tack welding or similar methods. This will allow you to check the overall shape and size of the fuel tank before permanently joining the halves.
At this stage, you may also need to cut out sections for the fuel filler, switch housing, or other components. Mark the locations for these cutouts, ensuring they are positioned correctly and won't interfere with the structural integrity of the shell. Cut out the marked sections carefully, considering the size and shape of the components that will be installed.
It's important to note that the cutting and shaping process may vary depending on the fuel tank's design and the material used. Some materials may require specific cutting and shaping techniques, so it's essential to have a clear understanding of the properties of the material you are working with.
Overall, the cutting and shaping of the shell involve careful measurement, marking, cutting, and refining to achieve the desired shape and size for your motorcycle fuel tank.
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Welding the tank together
Welding is the most straightforward method to fabricate a motorcycle fuel tank. To make the process easier, it is best to reduce the number of welds to a minimum.
When welding the tank together, it is important to consider the material being used, as this will impact the welding process. For example, welding aluminium may cause distortion, so it is important to dress this out before welding the tank bottom in. Steel, on the other hand, is a more common choice due to its strength and ease of welding.
The first step in the welding process is to tack the tank pieces into place to ensure proper alignment. This can be done by clamping or temporarily welding the pieces together. Once the alignment is correct, the pieces can be welded together permanently. It is important to ensure that the welds are strong and secure to prevent leaks.
One common welding technique for motorcycle fuel tanks is TIG welding, as seen in the example of welding together the two halves of a '70s AMF tank. To prevent warping from excessive heat, it is important to alternate the welding pattern. In this case, 1-inch sections of the seam were TIG welded in an alternating fashion from top to bottom.
After welding, it is important to check for leaks. This can be done by filling the tank with water or compressed air and looking for any visible leaks. Once the tank passes this initial test, it can be sent for professional leak testing and coating.
Overall, welding is a critical step in fabricating a motorcycle fuel tank, and careful planning and execution are necessary to ensure a strong and leak-proof tank.
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Testing for leaks
Preparation
Before testing for leaks, it is essential to prepare the fuel tank properly. Start by draining the gas tank completely, ensuring not a single drop of fuel or vapour remains. This step is crucial for safety, as working on a tank with residual fuel can create a fire hazard. Once the tank is empty, remove the fuel line by carefully depressing the clamp and easing the line off the nipple of the gas tank. Cover any spills with an absorbent material, such as kitty litter, to prevent the fuel from spreading.
Visual Inspection
Begin by visually inspecting the fuel tank for any signs of damage or leaks. Remove the gas cap to allow flammable fumes to air out, and use a flashlight to look inside the tank for any visible cracks, pinholes, or blemishes. If the tank is rusty, assess whether the rust requires mechanical removal or can be treated with chemicals.
Pressure Testing
Pressure testing is a reliable method to identify leaks in your fuel tank. Before painting your tank or welding it together, perform a pressure test to ensure there are no leaks, pinholes, or cracks in the welds or seams. This step is crucial to avoid ruining your paint job and to guarantee the tank's integrity.
Repairing Leaks
If you discover any leaks or pinholes, repair them accordingly. Weld up and fix any pinholes or cracks, following the procedures outlined in the resources. For rust removal, pour 1-2 quarts of acetone along with ball bearings, nuts, and bolts into the tank. Seal the fill hole with plastic wrap and a rubber band to prevent leaks, then shake and rotate the tank to remove the rust and create a surface for the epoxy to cling to.
Final Checks
After making repairs or modifications to your fuel tank, conduct another pressure test to ensure that the leaks have been adequately addressed. Follow the pressure testing procedures outlined in the resources to verify that your fuel tank is now leak-free.
Remember to refer to detailed guides and videos for specific instructions on pressure testing and repairing leaks, as the procedures may vary depending on your fuel tank's design and condition.
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Frequently asked questions
You can use materials such as steel, aluminium, copper, or fibreglass.
You will need tools such as a planishing hammer, an air-powered die grinder, a TIG welder, and various dollies.
You can create a pattern by sketching the side and top profiles of the tank, cutting them out, and assembling them to get an idea of the tank's shape and size.
You can test for leaks by filling the tank with water or fuel and checking for any visible leaks. You can also send the tank to a radiator shop for professional leak testing.
The best method for sealing a fibreglass fuel tank is to use an epoxy sealer.
