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7 gallon gas tank

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Old 11-25-2013, 07:55 PM
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7 gallon gas tank

In preparation to ride to Alaska and back, I decided to make a larger gas tank for my Hawk. I bought a damaged tank for $100. I cut the tank in half horizontally. Since I had located a vented gas cap, I decided to plug the vent and overflow tubes to make my job easier. My friend, Mike, welded a 4 inch band of steel between the two halves. I can now go at least 250 miles on a tank. The only problem that I encountered on the trip was a vapor build-up between the gas cap and my tank bag (I am in the process of making a spacer to place between the tank and my bag. Now I have a touring tank and a canyon tank. Total cost excluding labor was about $500.
Attached Thumbnails 7 gallon gas tank-damaged-tank.jpg   7 gallon gas tank-prep-welding.jpg   7 gallon gas tank-back-welder.jpg   7 gallon gas tank-old-new.jpg   7 gallon gas tank-finished-product.jpg  

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Old 11-25-2013, 08:03 PM
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Very nice. How did you cut it? Plasma?
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Old 11-25-2013, 08:48 PM
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Plasma? Way too fancy for me, used a 4 inch grinder.
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Old 11-25-2013, 09:46 PM
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That's pretty cool. Someone either here or on the VTR1000.org site did the exact same thing, but they only raised thier tank about 2-3" if I remember correctly.

Did you actually fill the tank with a liquid and see how much volume is inside, or is 7 gallons an educated guess?
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Old 11-26-2013, 10:54 AM
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Originally Posted by CruxGNZ
That's pretty cool. Someone either here or on the VTR1000.org site did the exact same thing, but they only raised thier tank about 2-3" if I remember correctly.

Did you actually fill the tank with a liquid and see how much volume is inside, or is 7 gallons an educated guess?
That was me. Back in 2003 I also used a special alloy steel and phosphate treated it before and after welding, then cleaned and coated the interior with POR15 two times.

I was actually thinking of selling it as whereas old age and treachery trumps youth and exuberance, one's prostate limits range to the OEM fuel tank capacity mileage...

The vented gas gap I found (though did not buy), as the OEM vent is intact is made by Yoyodyne, and accordingly is pricey.

Honda Rapid Lock Tank Cap Silver
Attached Thumbnails 7 gallon gas tank-after-top-vw.jpg   7 gallon gas tank-after-end-vw.jpg   7 gallon gas tank-long-range-vtr-2-c.jpg   7 gallon gas tank-long-range-vtr-c.jpg  
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Old 11-26-2013, 12:30 PM
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I want one
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Old 11-26-2013, 01:13 PM
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Originally Posted by insulinboy
I want one
Then make me an offer I can't refuse for my 5.25+/- gallon painted tank...
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Old 11-26-2013, 01:30 PM
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Originally Posted by skokievtr
Then make me an offer I can't refuse for my 5.25+/- gallon painted tank...
I def would if I didn't just blow a wad on a new gopro
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Old 11-26-2013, 01:35 PM
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Nice job. Better skills than me. Not making fun of your work because it sure looks shiny in the finished pic, but this is the first thing that popped into my head when I saw that Don't mind me I'm not all there sometimes...
Attached Thumbnails 7 gallon gas tank-tank.jpg   7 gallon gas tank-herman.jpg  
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Old 11-26-2013, 01:39 PM
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On a more serious note you said $500 excluding labor, I'm curious what you spent the other $400 on? Did materials add up that fast?

Last edited by captainchaos; 11-26-2013 at 01:42 PM.
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Old 11-26-2013, 02:15 PM
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Originally Posted by captainchaos
On a more serious note you said $500 excluding labor, I'm curious what you spent the other $400 on? Did materials add up that fast?
Maybe he included some new tools in the cost. looks like he used some rivets in the fab work and may have needed to buy a rivet gun, vented gas caps aren't cheap so if he splurged on that the vortex ones can go for $200 by themselves. I'm sure it could be done cheaper but I don't doubt that you could spend that much doing it as well.

Edit: as well he might not be including his labor in the cost but is including others labor. That was the way I read it anyway when I first read it.
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Old 11-26-2013, 03:00 PM
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Back in 2003, including the alloy steel, POR15, etching & phosphate materials, welding materials, used tank and petcock, paint materials + misc I spent over $500 plus my labor...
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Old 11-27-2013, 06:46 AM
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Originally Posted by CruxGNZ
That's pretty cool. Someone either here or on the VTR1000.org site did the exact same thing, but they only raised thier tank about 2-3" if I remember correctly.

Did you actually fill the tank with a liquid and see how much volume is inside, or is 7 gallons an educated guess?
That was me. I also used a special alloy steel and phosphate treated it before and after welding, then cleaned and coated the interior with POR15 two times.

I was actually thinking of selling it as whereas old age and treachery trumps youth and exuberance, one's prostate limits range to the OEM fuel tank capacity...

The vented gas gap
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Old 11-27-2013, 09:30 AM
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Crazy... Bsaically you've been doing this with the same bike for over 10 years? O_O
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Old 11-27-2013, 10:26 AM
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Originally Posted by mdouglas71
Crazy... Bsaically you've been doing this with the same bike for over 10 years? O_O
Doing what. I built my extended range tank in 03. I bought my VTR new in 1999 as a leftover 97 with free 1st service (last time a dealer touched it), shop manual and free replacement battery for about $7k OTD. Now at 85k+ miles with dozens of low-viz mods...
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Old 11-27-2013, 04:34 PM
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HAHHAHAHAHAH. The back-mounted 2nd tank mod is FTW!! Very well done sir I can't see the hoses so I'm assuming it requires routing them through the pants straight to the carbs. A bit risky but hell worth it for doubling the mileage.
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Old 11-27-2013, 05:29 PM
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If anyone on here had any brains they'd be strapping a second motor on their back. I'll give you that chain routing would be a bit tricky.
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Old 11-27-2013, 05:32 PM
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turtle tank

glad you enjoyed it

been a while since someone looked at the original of my thumbnail

Actually rode 110 miles with it on my back, empty on way to modding it.
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Old 11-27-2013, 05:45 PM
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Classic! Have you got a higher resolution version of the turtletback tank avatar thumbnail which will be a handy image to reply to the numerous miles per gallon / tank range questions.
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