Measuring, punching and drilling holes. General pre-assembly and cutting material to size.
The intent was to utilize as many direct-to-frame mounting locations as possible. This meant dealing with
The two forward-most holes which secure the BMW rear support to the frame have a forward sweep of
The front of the tank shown here, after a bit of grinding work to allow the nose of the lower plate to fit
Looking rearward at the tank, making the first tack welds.
These (3) posts are simply passageways to access the (3) rearward-most mounting points from the top
Also to keep warping (heat) to a minimum, the welds are kept short and distributed around the assembly.
Mitre-cut baffles are all in place & the rest of the internal welding is complete. The fuel outlet hole is
Welds brushed clean and the inside of the tank is wiped down with brake cleaner.
With the fuel neck & another NPT fitting for the vent both welded in, the top goes on over the (3) passageways.
A good bit of grinding here to get the top plate of the tank flush with the sides.
With the tank checked for squareness, the entire top plate is welded on, and outside welds are
I wanted to use the (2) mounting points on the side of the bike, and this required some careful fitting up
Custom aluminum spacers (heavy-wall tubing) are used here between the tabs and the bike frame.
I wanted to have the top of this tank as flush as possible ahead of the fuel neck to give the tank
A bit of test fitting to the bike after letting the smoke out of the shop....
The fuel outlet is very low in the tank - about 1/8" from the bottom - and with such a forward lean-angle,
Still more grinding work was done on the front area to allow fitment to the stock rear support & to
The fuel neck & roll-over vent are placed here to permit a tire to lay perfectly flat on top of the tank.
I was going to weld some tie down points to the sides of the tank, but there's an ample number of places
Back from being coated with Linex bedliner material.
Had to clean out some of the holes & prep for mounting.
All mounted & secured very tight to the factory threaded holes in the frame. Overflow hose also attached.
Aluminum spacers are used to take up the gap at all fastening points.
I spent a good bit of time searching for this 90 degree ball valve with 1/2" NPT male / female threads.
Inline 40-micron fuel filter. Ideally everything would be mounted on the left side of the bike instead
To my delight, removal of the charcoal canister provided a perfect & protected spot for the weldless bung.
The Pingle weldless fuel bung (P/N 62136) now lives where the charcoal canister once was.
The new 5/16" fuel line (lower) is secured well away from the telelever, and the right side tank vent
Would have hit $60 had the tanks been completely dry....