Topic: custom super sport tank

[Geeto67]

also what about a flush cap:

http://www.aircraftspruce.com/menus/ap/fuel_caps_flush.html

much cheaper plus you can tell people at bike nights that you have airplane technology on your bike.

[wannabridin]

Well as cool as the flush mount caps are, they aren't vintage enough for me.  And I know carpy doesn't make them, but they're on his site and he has them in stock, an he's goin to throw one in the box with my exhaust so I don't have to pay for shipping... It's a totally retro look for me, coupling the lines of the F tank and the K tank...

In order to reduce the risk of burning thru and flames, what are some good precautions I can and should take with welding the tank??

[Geeto67]

Well, you should rinse it out with soapy water and make sure there is no hint of fuel residue left. At the radiator shop I used to work at we used to "foof" the tank, which was to take a torch to the empty tank with all the caps and vents open to make sure all the vapors were burned up. It would make a foof sound and maybe a small amount flame but it would eat up the vapors quick. Much better than starting to weld on a tank and having it explode and rupture on you.

some guys fill the bottom of the tank with water to weld to help cooling. I have heard mixed reviews on this technique and personally I never saw any of our welders do it for as long as I worked at that shop.

how are you welding? Oxy? Mig? Tig? I think stich welding with mig will probably be your best bet.

airplanes had flush mounted fuel caps before motorcycles ever had monza caps. Some of the kit planes still use a vented cap that was designed for piper cubs in the 1930s (the cap and filler neck are $7 a piece) and were popular for choppers in the 1960s. 

[wannabridin]

 will be stitch welding with my Hobart handler 120.  It's a 120v mig welder, and I'll be using a .030" flux cored wire, probably put it on the lowest voltage setting.  I was going to do the "foof" method, I just didn't have a name for it, haha!  I'll do this after a good soapy water clean and lots of rinses...

I do understand the flush mount airplane fillers, and I respect the look when used properly, but personally, the monza style is just sexy to me.  I always think about a '66 428 shelby cobra when I see them!  I just can't wait to start fabbing this up!  I need to wait until I get the filler cap tho, hurry up carpy!!!

[wannabridin]

so i got the new gas cap in, and i just wanted to show the pics of it!  it's the one carpy sells, and it's REALLY nice!  let me know if y'all have any questions.

i'll definitely need to trim down the filler neck, but luckily, it will fit down into the tank just fine with minimal modification!  at least that's what i'm hoping....