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Discussion Starter #1 (Edited)
Okay, there we go.
There have been many question around this and will show you how it can be done. It is not done by me, as I do not have the welding skills.
Maybe it is some inspiration for others to follow.

Enjoy

Stock tank cleaned up:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-18-690.jpg.html][/URL]

Marking done:

[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-18-691.jpg.html][/URL]

Cheeks cut:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-18-692.jpg.html][/URL]

There is always some rust:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-18-693.jpg.html][/URL]

Let the widening begin:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-18-696.jpg.html][/URL]
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-20-710.jpg.html][/URL]
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-20-712.jpg.html][/URL]

Finished and cleaning up:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-25-720.jpg.html][/URL]
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-25-721.jpg.html][/URL]


Done, new versus old:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-25-726.jpg.html][/URL]

And the finished raw product, ready for internal treatment, external treatment and painting:
[URL=http://s851.photobucket.com/user/Flyingdutchman66/media/Warrior/Tank/2014-03-25-727.jpg.html][/URL]

So, I hope this takes some of the questions and the doubts away from certain members, e.g. can it be done, is the tank double skinned, etc.

Dutch :cool:
 

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wow...that makes my mouth water!!


I will PM you with my address so you can ship that off to me now!!

 

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How much extra fuel does it hold?
I'm gonna take a guess and say, those strips are 1-1 1/2" wide making it an additional 2-3 inches wider, so I'll say about a half gallon... Maybe. I'd like to know for sure, though.
 

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Discussion Starter #6
SnowBoy,

Yep that was a repair, that was some rust that came through, so needed to be fixed.

Dutch :cool:
 

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well, I like it and have been wanting to add about 3 inches to my tank... Or a donor tank, anyway. At least this thread shows that it can be done and it won't look gawky at all. Thank you, Dutch for this. Now I have another dream to shoot for... More miles per tank!
 

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Discussion Starter #8
I'm gonna take a guess and say, those strips are 1-1 1/2" wide making it an additional 2-3 inches wider, so I'll say about a half gallon... Maybe. I'd like to know for sure, though.
Diablito,

Many people asked me this question and I was always guessing, so I did the calculations:
Put a string around the weld: 1350 mm
The tank is not cylindrical but that does not matter for this calculation, so doing the math (Circumference=Pi * Diameter) : 1350 = 3.14 * D => D~430 mm.
Take away some for the welds and the thickness of the steel etc assume D=400 mm
D=2 * R => R = 400 / 2 = 200 mm
As the widening is tapered 25 mm at the back to 50 mm at the front (on each side) we can calculate that the overall increase is 25 + 50 = 75 mm
Now volume calculation:
Volume = Pi * R * R * H
Volume = 3.14 * 200 * 200 * 75 = 9424777 micro liter ~ 9.4 Liter
9.4 Liter ~ 2.48 Gallons.

This all is of course if you keep the tank upright during filling and fill her up to the absolute top. I never do this as the others :p need to fill up so much quicker so I guess I fill an extra 5 - 6 liters compared to stock

Dutch :cool:
 

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Nice, now all you have to do is run it dry and fill it up to check for accuracy. That part is easy and the most fun.
 

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When I welded my tank I checked for leaks 5 times, one pin-hole would get filled and another would open. Then when I was positive it wouldn't leak I pressure tested it and then applied Por-15 to the inside. This stuff was awesome and I highly recommend it, you don't want to ruin an expensive paint job when your tank decides to take a leak.
 

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Discussion Starter #11
When I welded my tank I checked for leaks 5 times, one pin-hole would get filled and another would open. Then when I was positive it wouldn't leak I pressure tested it and then applied Por-15 to the inside. This stuff was awesome and I highly recommend it, you don't want to ruin an expensive paint job when your tank decides to take a leak.
Agree, you did a great job with your mod.
I did get the inside as well as the outside treated because welds are very prone to rust. My last tank did last me over 6 years before I damaged her...

Thanks for the comment and advise, will help others as well

Dutch :cool:
 

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Quote: Put a string around the weld: 1350 mm
The tank is not cylindrical but that does not matter for this calculation, so doing the math (Circumference=Pi * Diameter) : 1350 = 3.14 * D => D~430 mm.
Take away some for the welds and the thickness of the steel etc assume D=400 mm
D=2 * R => R = 400 / 2 = 200 mm
As the widening is tapered 25 mm at the back to 50 mm at the front (on each side) we can calculate that the overall increase is 25 + 50 = 75 mm
Now volume calculation:
Volume = Pi * R * R * H
Volume = 3.14 * 200 * 200 * 75 = 9424777 micro liter ~ 9.4 Liter
9.4 Liter ~ 2.48 Gallons.
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QUOTE: Nice, now all you have to do is run it dry and fill it up to check for accuracy.

---------------------

mmm......I wonder which way I would have worked it out?


Well - come on guys...I'd have done the maths of course! :eek::rolleyes::eek:
 

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good write up thanks. this lends hope to those who have tanks with a big dent as once the tank is sliced it would be very easy to hammer out the dent and kill two birds with one stone so to speak. repair an otherwise unrepairable tank and increase the the fuel capacity at the same time. I just happen to have one of those dented tanks lying around so I now know its future.
 

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Dented tanks can be repaired from the outside.

Most if not all cage body shops should have a stud welder gun. Numerous studs are welded to the dented area, a slide hammer is used on the studs to work the dent out.

If you have a welder, slide hammer & some 10 penny nails you can DIY.

Tank looks good Dutch!
 

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Dented tanks can be repaired from the outside.

Most if not all cage body shops should have a stud welder gun. Numerous studs are welded to the dented area, a slide hammer is used on the studs to work the dent out.

If you have a welder, slide hammer & some 10 penny nails you can DIY.

Tank looks good Dutch!
yeah, but why stop at just fixing the dent when you can improve fuel range at the same time? I would rather be able to squeeze 200 miles from one tank than have to fill up every 110ish.
 

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also my tank is creased pretty bad. I originally bought it just to do set ups on my bike so i wouldn't screw up my good tank however now it will become fat like the rear
 
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