You need a vented cap to allow air to enter the tank as fuel exits. The vent on the stock cap will often plug up with corrosion and cause a stalling problem after a few miles, similar to the sputter you'd get when it's time to switch to reserve on your petcock. It's an easy problem to troubleshoot, just open the cap when it starts to sputter...if the sputtering disappears, you've got a venting issue. I don't know a thing about sportster tanks or how they're vented, but I'll bet someone here does.
Sounds like a cool project, are there pics up someplace? (other than your avitar?)
Good luck working out those details too!