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Looking for someone to repair and modify a fuel tank. 21 Nov 2021 12:44 #858162

  • Nerdy
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Have you considered repurposing an existing tank from another bike?

Here is one from a 1981 Suzuki GS450:

1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Looking for someone to repair and modify a fuel tank. 22 Nov 2021 09:57 #858188

  • DoctoRot
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To modify the tank like that will be a lot more work than you think. Ideally the entire top of the tank would be cut off from the tunnel so that the panels that are welded in can be worked from both sides. Not being able to hammer and dolly the weld seams on the large radius curves almost guarantees you will need lots of body filler. Most of, if not all, the top and back of the tank would probably need to be cut out and re-made to ensure continuity through the curves. This would likely necessitate reworking the sides as well, and at that point it becomes easier to remake the entire top portion because the steel on these tanks is very thin and the quality is not great.

its not 1950 anymore most body shops are strictly R&R and finding someone with the skills to do something like this in a clean fashion will not be cheap.

Cutting the top of another tank and adapting it to your existing tunnel is a great lower stakes way to get a tank change.  Alternatively you can modify a complete tank like Nerdy mentioned.

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Last edit: by DoctoRot.

Looking for someone to repair and modify a fuel tank. 22 Nov 2021 12:19 #858199

  • Stereordinary
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Thank you for the thoughtful responses. I started this thread because frankly I don’t know enough about this stuff to really know if it’s even possible. As we’ve gone along here, and I’ve talked to some other folks, it seems most likely that what I’m thinking is far more work than is reasonable. 

I do have a request in with Doremi Collection to see if they can make it from scratch. But they had asked about how many I wanted to order, which I assume means they are only going to do it if I meet a minimum. I suppose I can ask here, would anyone else be interested in a tank like this for their Zephyr 550? I can start a new thread for that question, unless someone wants to tag all the other ZR550 owners here. 

Another idea I had, and one that I was thinking I might be foolhardy enough to try myself is to create the tank out of fiberglass or carbon fiber. This would of course still be difficult and expensive, but seems a little more within reach as far as my personal skill set is concerned. 
A breeze from the west.
‘90 ZR550 Zephyr aka Zephanie

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Looking for someone to repair and modify a fuel tank. 22 Nov 2021 13:35 #858216

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You could build a fiberglass shroud that covers your actual tank, then you don't have to worry about sealing it or getting a fuel cap to work

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Looking for someone to repair and modify a fuel tank. 22 Nov 2021 13:58 #858218

  • z1kzonly
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No offense. But, just why?
Call Jesse James, or OCC, they need business. Maybe contact the Discovery Channel, ask them to help you out with a metric Japanese bike project! Hey, Ya' never know!
I'd start searching the Harley builders, Money is money! They might take on some work!
I grew up with the infamous "PUPPET" from Racevisions fame. He was a master fabricator, RIP PUP! He hand made a lot of famous projects.
Including Elmer Trett, Larry Spiderman, Jim Da Judge McClure. He built chassis and hand formed bodies. All by his brain and hands! Before any Cad Cam, Program this or that!
You need a hand fabricated tank, welded up together.
Or just leave it! Sorry to be sarcastic! But bad day in Western New York! The local Chi-Commies mandated masks tomorrow. Leaving you home!
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Looking for someone to repair and modify a fuel tank. 22 Nov 2021 14:48 #858221

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No offense. But, just why?
 


Why not? A lot of us do things to our bikes to make them ours.

Is it a practical way to spend money? I dunno - probably not. But that's not the question at hand.
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R
The following user(s) said Thank You: 750 R1

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Looking for someone to repair and modify a fuel tank. 23 Nov 2021 10:45 #858245

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You could build a fiberglass shroud that covers your actual tank, then you don't have to worry about sealing it or getting a fuel cap to work

Thats not a bad idea. Certainly would save me a fair bit of headache. 
A breeze from the west.
‘90 ZR550 Zephyr aka Zephanie

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Looking for someone to repair and modify a fuel tank. 23 Nov 2021 10:48 #858247

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No offense. But, just why?

 


Why not? A lot of us do things to our bikes to make them ours.

Is it a practical way to spend money? I dunno - probably not. But that's not the question at hand.
 

Yeah, isn’t the answer obvious? Because it looks cool, haha. 

I definitely have other things I want to do with the bike, all of which are performance-related. This is the one thing I want to do that would actually change the look of the bike. Well, besides paint anyway. Everybody’s gotta make their bike their own right?
A breeze from the west.
‘90 ZR550 Zephyr aka Zephanie

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Looking for someone to repair and modify a fuel tank. 23 Nov 2021 17:47 #858268

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You could build a fiberglass shroud that covers your actual tank, then you don't have to worry about sealing it or getting a fuel cap to work

Thats not a bad idea. Certainly would save me a fair bit of headache.  

This type of fuel tank construction is not uncommon on race bikes. I'm planning on doing something like this for my 750 track bike. small aluminum tank with composite shroud. 
 
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