Things You'll Need:
- Sheet metal
- Benders
- Mallet bag and mallet
- Welder
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Step 1
Trace the shape of the tank sides, top and bottom onto 12-gauge sheet metal, allowing extra space so you can bend the sheet metal into shape.
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Step 2
Cut out the shapes for each side of the motorcycle gas tank using a pair of metal cutters.
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Step 3
Bend the edges of the sides using a metal bender or metal curler until you achieve the shape you desire.
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Step 4
Set the two sides onto a form and tack weld them together at both ends.
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Step 5
Bend and curl the sides of the top of the gas tank, then lay it on a mallet bag and pound the top into shape, putting the curve into the metal that you desire.
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Step 6
Lay the top of the gas tank onto the form and tack weld it to the two sides of the gas tank. When satisfied that the tank is coming together the way you like, complete your welds by making a strong 1/4-inch bead along the entire length of the seams on all sides of the tank.
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Step 7
Remove the tank from the form. Now, curl the edges of the bottom sheet and tack weld it to the gas tank. Check to ensure the bottom fits perfectly to the tank, trimming any excess and making any necessary adjustments. Then complete the weld.
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Step 8
Cut a hole for the gas cap using a circle drill bit with carbide-tipped teeth. Then fit the gas cap and gaskets to the tank, welding it into place.
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Step 9
Cut a hole for the petcock valve in the bottom of the tank using a smaller carbide tipped circular drill bit and install the petcock valve, welding it into place in the same fashion. Weld the necessary frame hardware to the gas tank to attach it to your bike frame.
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Step 10
Grind down your weld seams with a metal grinder, then prime and paint your gas tank.
