First, view the pictures. This will give you the visual information on this mod.
1. Manifolds- First, purchase new manifolds. I find David Silver Spares a good source. You will need a 1-1/16 and 1-1/8 hole saws. Mount the manifold to a board with wood screws and push the 1-1/16 into the manifold, minus pilot bit. Set the board onto the drill press, lower the chuck onto the hole saw and tighten chuck. Clamp board to the table. This centers the manifold. Raise the chuck, remove the 1-1/16 and install the 1-1/8. you want to only remove material down to the original shoulder inside the manifold, 5/8". Done.
2. Fuel petcock- purchase a Parts Unlimited 5/16" tap as shown. Carefully remove enough material off one hose barb to use an 8x1.25 die, and thread.
Have a machinist make the collar of suitable stainless stock, 10mm long and threaded to 20x1.5mm (20 is my measurement, take tank and have it measured-1.5 is the thread). purchase a suitable ss washer and 8x1.25 nut, take to a good tig welder and weld it all up. I wrapped the yellow Teflon tape on the tap and tank to seal- no leaks. But no reserve. I made a small 1 qt. tank that looks like an air filter and stashed it in the now unused airbox.
