Topic: Cutting and welding tank filler

[The Sovereign Man]

Here’s what I have



I’m not looking to restore this tank, just get it functional.

It looks as though it’s been stored upside down as the only rust (aside from surface rust inside) is around the filler.

Has anyone had success cutting and welding a tank? My thought was I could cut the top out of an equally rusted tank that has a decent filler and weld it in place.

Am I taking on a difficult job that would’ve easier solved by buying another tank?

[ekpent]

 I'd be hunting for another tank but I am not a welder/fabricator like some around here. 750 supersport tanks are hard to find,not sure on the 550's. Good luck if you take it on.

[The Sovereign Man]

I'd be hunting for another tank but I am not a welder/fabricator like some around here. 750 supersport tanks are hard to find,not sure on the 550's. Good luck if you take it on.

Seems a shame to waste this tank as it’s otherwise in good condition.

[madmtnmotors]

Welding fuel tanks can be extremely dangerous and usually requires purging the tank with inert gas during welding. It can be done, but I would seek out a welder experienced with fuel tanks, either for advice or preferably to do the work for you.

[The Sovereign Man]

Welding fuel tanks can be extremely dangerous and usually requires purging the tank with inert gas during welding. It can be done, but I would seek out a welder experienced with fuel tanks, either for advice or preferably to do the work for you.

Got it, cheers.

[maxheadflow]

You could try and cut along the panel cover step and see if there is enough to weld in a panel with a fuel inlet. Some custom places will have flush mount caps which are kind of cool.  If it's really rusted I'd dump the tank.  If you decide to weld, you really don't need inert gas. Low flow air will work. The idea is it use enough air that the mixture burns too slow to pop the tank.

[The Sovereign Man]

You could try and cut along the panel cover step and see if there is enough to weld in a panel with a fuel inlet. Some custom places will have flush mount caps which are kind of cool.  If it's really rusted I'd dump the tank.  If you decide to weld, you really don't need inert gas. Low flow air will work. The idea is it use enough air that the mixture burns too slow to pop the tank.

This was my plan. I’m not concerned about keeping the door on the top, any filler will suffice as long as it is functional and not too ugly on the eye.

[The Sovereign Man]

Failing a weld job, what tanks are interchangeable on a 550K4 without making modifications?

[jonda500]

550K3 or any 550F tank are the only direct swaps I know of - but the petcock may be different. Earlier 500/550 tanks will fit if you get the older seat as well. I have a spare 550K4 tank that I may be persuaded to part with for the right price.
John