More Gas (How I made a tank bigger - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 78 (permalink) Old 02-21-2011, 08:51 PM Thread Starter
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More Gas (How I made a tank bigger

Bought a used tank on Ebay.



Here's why it was cheap.



















The welds have been ground and all the seams are LEADED. I have a dual outlet Pingle but the weld bung is backordered. I'll post more when that is done.

1986 VN750A(2) 12224 miles.

Last edited by junkyardroad; 03-28-2011 at 09:45 PM. Reason: sp
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post #2 of 78 (permalink) Old 02-21-2011, 09:04 PM
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Interesting approach jyr.
I`ll be curious to see how much more fuel it will hold. I expect about a gallon maybe??

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
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post #3 of 78 (permalink) Old 02-21-2011, 10:59 PM
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What equipment did you use? To cut and weld and stuff...
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post #4 of 78 (permalink) Old 02-21-2011, 11:57 PM
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With nice cuts as those.. it looks like he used a die grinder to make the cuts.. and a regular mig to weld it up.. an angle grinder to grind own the welds, then he used lead to fill in the pinholes left by welding
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post #5 of 78 (permalink) Old 02-22-2011, 06:53 AM
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Nice! These tanks are really thin compared some of what else is out there... which definitely doesn't make the job any easier!
I guess you plan to seal it like you would a rusted tank, when you're done?

Good Luck!

05 VN750
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ignition pickups gapped
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sissy bar
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6k miles

PW50, XR50, TTR90, XR100, DT175 (2-smoker), CRF230F, XR250R (dual sported), XR400R 4 KIDS, LOL!

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post #6 of 78 (permalink) Old 02-22-2011, 08:37 AM
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You will have some prospects with this done & fitted. I'm pretty sure there's some money to be made here! More Gas, Awsome! So many want a bigger tank.

Oh Yeah, Great Job So Far.
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post #7 of 78 (permalink) Old 02-22-2011, 12:28 PM
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How do you use lead to fill in the holes in the welds? Just heat it up and apply it? Lead electrode? Lead wire?

I'm asking cause a friend had a leaking tank, he took it to a lot of people and no one seemed to be able to seal it. They kept trying to weld it and they never got it to stop leaking. I suppose they have no idea how to use lead for this over here, so it might be good to know how it's used so at least I can tell them if I ever need it.
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post #8 of 78 (permalink) Old 02-22-2011, 02:08 PM
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Since the project is not done and on the bike, you don't yet know how this will affect your turning. The handlebars come really close to the tank in factory condition, this will mean the bars will contact the sides, I'd imagine.
I wonder if making the tank taller would have been a better way. The center of gravity might be affected going the tall route but you can't have everything.
Any real effort to increase fuel capacity deserves a definite applause to the tinkerer.
Many people are waiting to see how this turns out since lack of range affects us all.
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post #9 of 78 (permalink) Old 02-22-2011, 02:20 PM
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Quote:
Originally Posted by Ceal View Post
How do you use lead to fill in the holes in the welds? Just heat it up and apply it? Lead electrode? Lead wire?

I'm asking cause a friend had a leaking tank, he took it to a lot of people and no one seemed to be able to seal it. They kept trying to weld it and they never got it to stop leaking. I suppose they have no idea how to use lead for this over here, so it might be good to know how it's used so at least I can tell them if I ever need it.
I`m not a bodyman, nor have I ever seen lead used, but before light weight fiberglass body filler was available, lead was used (and often overused) for autobody repair. I imagine it is applied somewhat like solder, but using the lead in bar form. Hopefully someone experienced in it`s use can elaborate on the process.

Gordon

1991 VN 750 -"Cosmic Lady" or "Bad Girl"?
Purchased May 16, 2008
Approx.19,300km (12,000 miles)

H-D windshield
Relocated R/R
MF-AGM battery
Fiamm Freeway Blaster horns
F&S luggage rack and engine guard
Kury Offset Hiway pegs
July 13, 2016, Riding on the DARKSIDE now, Classic Radial 165/80-15


TOP TEN THINGS A NEW RIDER/OWNER SHOULD DO. Click on link.
https://www.vn750.com/forum/showthread.php?t=9127
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post #10 of 78 (permalink) Old 02-22-2011, 02:50 PM
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Quote:
Originally Posted by Ceal View Post
I'm asking cause a friend had a leaking tank, he took it to a lot of people and no one seemed to be able to seal it. They kept trying to weld it and they never got it to stop leaking.
Use this, it works: http://www.caswellplating.com/aids/epoxygas.htm

I'm keepin' all the left over parts. I'm gonna use 'em to build another bike!
_____________________________________________
"Black Beauty"
1989 VN750 acquired December, 2008, 6,711 miles
Currently 23,298 miles

Old Blue
2001 Honda CMX250 Rebel acquired July, 2008

1987 VN750 project bike, acquired August, 2009, 33,000 miles and balancer sticking out of the case, currently awaiting attention and parts
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