4. Increasing petrol tank capacity...

A blow by blow photographic account of chopping from stock to chop... This projcet has been given its own forum due to the large number of photos it contains making uploading slow for those of you still on "dial up".
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Prof
Founder, Choppers Australia
Posts: 5757
Joined: Sat Oct 22, 2005 3:54 pm
Location: Willunga, South Australia
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4. Increasing petrol tank capacity...

Post by Prof » Mon Nov 06, 2006 10:10 am

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This style tank came from Hummer originally, I think. Was also used on Sprint and then on Superglide. Now it's going on the Sportster...

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Used angle grinder with 1mm blade to cut out tunnel. Hole saws to remove tap mounting and filler cap.

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Turned up a piece of round nylon stock as a locator for hole saw. Fits neatly inside tap mount and slides over drill bit. SAme system used for filler cap, but locator made from a piece of wood. Works fine... see previous pic.

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Made up a mini bender out of old piece of bent square steel bar. Works a treat to crimp edges so I can weld in steel plate with out welding being proud.
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this piece also has its edges crimped. Reduces amount of body filler needed to smooth things over.

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Had to cut lip of filler spout and weld it to a piece of exhasut pipe that was exaclty same diameter. This protrudes into tank a couple of inches to reduce splashing. Slots are to allow air to escape as tank nears full.

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Tunnel welded in. Tank will sit on top of frame to give maximum range and also to look really classic chop. Gas welded with steel. Was going to get it TIG'd (quoted $60) but would have had to wait a week and Michael wants to get onto moulding it before he has to go back. Bottom got a bit buckled, but will do.
Chopit'nrideit... Prof

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