Major modifications to tank / welding etc..

testarossa wrote: Just an idea about changing to a modern gas cap. Find a cheap, beat up tank on Ebay with the style of cap that you like. That way you can cut out the sheetmetal around the cap. Just take an extra inch around the circumference of the cap so you have something to weld to. Then cut out the same size hole in the top of your KZ tank and then weld it in. Make sure to keep the hole very close to the same shape as the donor filler neck piece. You don't want to be trying to weld across big gaps with that thin of sheetmetal. It burns through way to easy if your fitting job isn't precise.

+1. I did the exact same thing to my brother in laws foxbody. We put the fuel door off an '02 on his '91.

here is a tank i welded a flush mount cap from a rz350 tank into.








i use a tig.

but like andy and testa said some .023 mig wire should be able to get the job done.

a hose off of an exhaust pipe ran into the gas tank is good way to remove the gas fumes.

a cutdown bicycle inner tube (with the schrader valve in it) with one and plugged and the other end hooked to the tank is a good way to pressure test a tank. it gives a you visual reading on tank pressure and keeps you from buckling the tank.then just spray the outside with some soapy water and look for bubbles.


leon

Leon, im inspired after seeing that! Just have to locate a flush mount cap now. Looks like the same tank I've got also. I've got to at least say I tried.

Damn Leon, you sure know how to screw up a good paint job dontcha.

testarossa wrote: Damn Leon, you sure know how to screw up a good paint job dontcha.

you know i do!

heat is the easiest way to remove paint i know of :woohoo: .


leon

Damn Leon that looks good!! But I gota admit, im a bit SKEERED!! (to screw up my tank)

thanks for the kind words guys.

i always look at it like

"i'm gonna fix it, OR f@ck it up where nobody can!!!!!! ". :evil:

thats just me tho :laugh: .

leon

531blackbanshee wrote: thanks for the kind words guys.

i always look at it like

"i'm gonna fix it, OR f@ck it up where nobody can!!!!!! ". :evil:

thats just me tho :laugh: .

leon

That's awesome! I'm gonna use that line.

531blackbanshee wrote: thanks for the kind words guys.

i always look at it like

"i'm gonna fix it, OR f@ck it up where nobody can!!!!!! ". :evil:

thats just me tho :laugh: .

leon

Ha ha ha..

Yeah, thanks for showing me that perfectly flat filler, now thats the one I have to have. What year tank is that by the way?

i wanna say it is a 78 tank.
it is the smaller ltd tank.

you can do it.


leon

before you weld the tank if fuel fumes are a problem take you tank toa radiator shop and have it boiled. it will take care of the fume issue and remove the paint and any rust inside. weld away.

i have a z1 tank with a zx filler cap and second petcock add. they were brazed in .
it looks pretty good. i have shied away from using it since the z1 tanks are smaller. so i use a non modified kz tank.