Aluminium tanks - more DIY

  For the early part of the season, we had been using fibreglass fuel tanks on the Ducatis and after some problems caused by the increased amount of ethanol in modern fuels, had already re-sealed them with tank liner.
   What we really wanted was period style aluminium  tanks.
We had a look at some available for sale/to order, but in all cases they were either:

• Expensive
• not really the style we wanted
• there was a long waiting list                         
• In some cases all three of the above                                         

 The answer, have a go ourselves, Andy did a lot of research and started work.

 After deciding on the style the former or plug was made from shaped pieces of plywood

The tank would be made from five separate pieces and then welded together. The photo below shows the top and sides fitted to the former and the basic tools used. The glove is filled with sand and used to "hammer" some of the shape

A base was then cut to match

The top needed an indent and hole for the fuel cap, we decided against the usual Monza style cap and found some screw on types.

Indents were added for the fuel taps and the inner piece formed to fit over the spine of the frame

Finally bosses were added for the fuel taps and all the components welded together, ground flush and polished. Now fitted to the bikes we think they they are a great improvement

We learned a lot, not least why ali tanks are either expensive or there is a long waiting list.
I make this sound easy, it isn't, and all credit to Andy for his efforts