DIY
After changing the seat and bars on your bike all by yourself, you stepped it up and yanked the front fender completely off and did a bit of modification to the rear. You are now at a crossroads; do you pay some guy $1,500 for one of his custom one-off tanks or try to do it yourself? Well, if you are a monthly reader of HOT BIKE, then you know we suggest the latter. It's high time you stepped up your game and made yourself the gas tank of your dreams.
Luckily for you, Paughco has made the need for a planishing hammer and expert metal working skills a thing of the past with its Build Your Own tank shells and parts. They can supply you with six different shells and all sorts of tunnels, mounts, and bungs to build the perfect tank. Don't be scared. If you have done even a smidgen of customization to your own bike, with some patience you can build your own tank. We bet that you already have most of the tools in your garage to do the job right. Of course years of skill can help in the process of building your own tank, but the key is making precise measurements and taking your time.
To show you how easy it can be with one of these tank kits, we went back to the old school and decided to use only a die-grinder, air sander, hand file, chop saw, air compressor and a TIG welder to slice this tank into greatness. Follow along with us while we build ourselves a sweet little chopper tank.
The Lowdown
Man Hours: 11
Difficulty: Moderate
Aftermarket Parts Used: Paughco tank shell, Paughco screw-type gas filler, Paughco 3/8-inch NPT petcock bung, Schorr Metals 2x2-foot 16 Gauge Sheet Metal
Total Cost: $133.84
1. We started with Paughco's...
1. We started with Paughco's King Sporty tank shell ($74.95), screw-type gas filler ($36.95) and 3/8-inch NPT petcock bung ($8.95).
2. Taking a look at a stock...
2. Taking a look at a stock '70s AMF tank we knew that we had to cut the shell to attain the size we wanted.
3. After some deliberation,...
3. After some deliberation, we measured 3 1/2-inches to be sectioned from the center of the tank and marked it with masking tape.
4. Using an air-powered...
4. Using an air-powered die grinder we carefully cut along the taped lines.
5. We put the two sides...
5. We put the two sides of the sectioned tank together and checked for high spots between the halves.
6. We then removed them...
6. We then removed them with the sander until the halves fit flush. This step took more than a few times.