EXPANDING 1500-SE GAS TANK TO 5+ GALLONS

I have an SE with a 3.2 gallon tank that I modified.  First, I bought a spare tank for $50.00 as I was reasonably sure it would take awhile to modify the tank. Second, with a saber saw (some call it a jig saw), I cut the top of the tank off of the bottom (the part with the mounts), close to, but above the seams on the bottom. Third, I cut the top part in half from front to back (so you have a left and a right piece). Since the gas cap is in the middle, my otherwise straight front to back cut made a jog around the filler port.  I made four (4) 90-degree cuts around the port to make it way easier for the welder when he welded it back together. Now my gas cap is off center to the right 1-1/2". I like that look. It moves the cap to the right a piece, and it’s higher when the bike is on the side stand at the gas station. Fourth, weld 3" wide steel sheet (or whatever width you choose) of the appropriate thickness (your welder will know, but err on the thick side as its flat and might dent) between the two halves. Then weld the top and bottom together using 1-1/2" wide sheet to connect the top piece to the seam on the bottom piece. This is the hard part.  Because of all the curves, my welder pieced it together. I'll be taking some pictures and snail mail them to you if you like. The two tanks I have each had different vents built into them, your welder will have to figure out how to reconnect them.

If you make the tank too wide it might interfere with the forks. Before I had mine welded, I duct taped it together with cardboard strips so I could see what it would look like and how it would fit. If you use a lot of duct tape it will be watertight and you can fill it with water to check the capacity. As the duct tape has some flexibility, your actual capacity will be a bit less. You will want to strip the paint; I stripped mine after I cut it so that the paint would protect the tank as I made cuts. Buy the best stripper because it's tough paint.  Good luck and fire away with the questions. (Today I switched to reserve at 164 miles, and I have 1.5 gallons in reserve, I'm thinking of shortening the petcock tube to give me less reserve)  ThomBoz, v5858, thomboz@yahoo.com

TECH TIP: I had a problem with my 89"bubf leaking also.  It leaked from around the front mount brackets.  The spot welds on the brackets cracked loose.  What I ended up doing about 4 years ago was putting some JB weld all the way around the bracket.  It hasn't leaked since.   mrtater V~1424 89"bubf 99Nad

TECH TIP: When I bought my bubf, the tank had a rubber sealer already applied inside the tank. Apparently, when they did the seal they didn't bother making sure the vent tubes were not plugged up. Now my tank has no venting except through the lid and through the carbs when the tank pressure builds. I Think, because of this, gas push's into the carbs and on into the cylinders and crankcase when the bike sits for any length of time. Every spring I have to drain the oil and blow the cylinders out before riding. If I let it sit for any length of time, (weeks), the plugs fowl upon trying to start it. I suggest that when sealing a tank during or after they put the sealer in, that they blow enough pressure through all the vent tubes or even if possible, tape them from the inside before sealing. I believe the vent tubes come out right at the lid. At this point, this is only speculation but I would almost bet it's more accurate than not. It makes sence to me anyway.  mrtater V~1424 89"bubf 99Nad