fush mount fuel cap

any one fitted a flush mounted fuel cap to an old kz tank, any tips?

badkaw has a j-model he put one in.

KZR member 'kano' did one too' on an ELR tank...see the following:

kzrider.com/media/kunena/attachments/leg...no__s_kz1175r105.JPG

Thanks, looks like a kwaka brand cap as well

There was someone else who cut in a new cap from a different Kawi's tank. He had a welder cut out the area 3-4 inches around the other/flat cap tanks cap and welded it to a hole he made in the existing tank. Then the whole refinish thing....

OK, so I need to cut around the the filler cap on the doner tank and weld it into the same size hole made in the z tank. never thought of that, thanks heaps:cheer:

Just be sure to fill the tank partially with water, and don't heat it up too much because it WILL warp.

good point, will do, cheers

bad kaw's j-model flush mount cap.

thanks 531, next thing is to find a suitable doner tank.

Oy! Hey, sorry it took me a minute to get this thread...for some reason it was regitereing "read" on my computer...whatever.
Anyway: Yes, that's my tank; I've done it on at least three tanks, your welder needs to be the man as the metal is pretty darn thin. My machinist is a perfectionist and he told me that it's not a job for a shade-tree guy (like me). Make sure that you keep the drain tube so that you can have it welded in and routed on your new tank...if you don't keep it a tiny fuel spill over would turn into a messy clean up.

I have a friend with a salvage yard and I told him I wanted a bashed tank that had a good fuel cap with surrounding metal. He gets too much money for fuel caps, so what I ended up doing was watching eBay for cheap fuel tanks (remember they can be beat-up pretty bad as long as the material around the cap is still good) and I've purchased several and done the "J" tank you see above and a CB900F tank, and a GS1150ES tank and a GS1000E tank (that my friend had to have...so I sold it to him). But anyway, it's very do-able. My tank has black paint on it in that pic because I wanted to protect the bare metal during my 'mock up' of my project.

Good luck on your project and just drop me a line if you have any questions that I might be able to answer!
-KR

thanks badkaw, I'm looking at some tanks this week at a wrecker, he wants $50au for a complete tank smashed of cause. Said he sells the caps to builders of boats and speedway racers
did your machinist use a mill with a fly cutter? I was thinking just mark it out then use a dremel or 4" grinder to cut it out, the mill would definatly be more accurate