Matt Hotch Designs' Custom Motorcycle Gas Tank

Hidden Crossover And Flush Gas Cap

The Devil started by determining the proper spot on the tank for the weld-in crossover inserts.

It all began with careful measurement of the tank and the use of a square to ensure both sides lined up properly.

Once the insert measurements were made...

...the Devil drew an outline of the inserts right onto the gas tank.

To get the hole started, he used a die grinder with a cut-off wheel. A drill bit could also be used.

Then it was time to bust out the air saw to finish the cut and get it nice and smooth.

Once fitment was double-checked, the insert was TIG-welded into place. For this job, a MIG weld would suffice, but TIG makes for a better end product.

Moving on to the other insert, the Devil finished up the hole with a rotary grinder before welding in the insert.

Here's a look at the crossover tube attached to both of the inserts on the bottom of the gas tank.

The Devil put the tank on the frame's backbone to check for fit and finish of the new crossover, with the screw-in plates added for concealment.

Next up was adding the flush-mount gas cap to the top of the fuel tank.

The Devil started with the cutting wheel and die grinder to cut out the old fuel inlet, followed by the air saw to get the hole true and clean.

Then the new bung was placed into the hole, held with magnets, and checked for fitment before TIG-welding the bung into the gas tank.

Once the metal was cool, the pop-up cap was installed into the hole.

A perfect fit-the cap and bung are flush with the top of the tank.

Regardless of how simple something seems, the Devil always runs through the instructions to make sure he has all the parts and understands how a product works, how it's installed, and what its intended application is. "The Devil" of Lucky Devil Metal Works had used Matt Hotch Designs' gas caps and kickstands for quite some time when he heard about Matt's new Flush Fuel Crossover kit. The kit hides the fuel crossover line under the gas tank and out of sight with the help of two weld-in tank inserts and a metal plate to conceal the hose. It's a pretty straightforward operation but requires cutting and welding experience. Since the Devil was already busy on a customer's gas tank, he decided to install Hotch's Flush Mount Gas Cap with the weld-in steel bung during the same session.

Follow along as the Devil slices and dices while dancing around flying sparks.

After all the welding was done, the tank was pressure-tested to ensure a leak-proof container. A pressure regulator makes this job easier and safer-you want a max of 10 psi. Too much pressure can distort the shape of the tank.