Road Star Forum
Welcome, Guest
Please Login or Register.    Lost Password?
2" Fuel Tank Extension - Step By Step
Go to bottom Post Reply Favoured: 0
TOPIC: 2" Fuel Tank Extension - Step By Step
#275226
TampaSVT (User)
Life is hard. It's harder if yer' stupid(J.Wayne)
Platinum Boarder
Posts: 5065
graphgraph
User Offline Click here to see the profile of this user
Birthdate: 1965-07-03
2" Fuel Tank Extension - Step By Step 4 Years ago  
I scored a tank extension off of Ebay for $25.00+ shipping. It basically matches the shape of the tank, but still requires a bit of massaging once it's tack welded on.



After measuring and re-measuring (10 times), I tacked welded the center portion and started the afore mentioned "massaging". It's at this point that I decided to allow the
extension to take a rounded slope vs following the tank straight down. I didn't want the end of the tank to sit higher than the front edge of the seat.
Lower is better as the seat can sit slightly above the tank.

Basically, the next step was to press and tack all the way around. Then I went back and filled in any spaces I skipped.
*** Word of caution: Our tanks are not very thick. It's easy enough to burn all the way through (trust me). On the inside, I simply bent and shaped the edges
around using welding pliers so it looks natural.



Once it's welded all the way around, I ground all of the welds smooth so there were no high spots. Hard parts are done...



With a thin layer of filler, I built it up to blend the original shape of the tank with the shape of the new extension.



Once all of the prep work is done, a few good coats of primer and it looks like it's always been there.






Not an easy project. Probably 18-20 hours total and a 5 on a scale of 1-10. But, not really that bad for a home project. Really, the hardest part was stripping the tank to bare metal.

Next step is to test fit it and see how much a seat will have to be reworked to match up to it.
 
Logged Logged  
 
Last Edit: 2010/04/19 20:13 By TampaSVT.
 

2008 Road Star
Tricky Air Ride(remote controlled)
6-degree Raked Front-end
Ape Hangers Internal Wiring
RoadHouse Dooleys
Featured in V-Twin Magazine, August 2012

Online Photo Album
  The administrator has disabled public write access.
#275227
Boatmark (User)
Roadie fan, just blowin' down the road...
Platinum Boarder
Posts: 5248
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Location: Newport Beach Ca. Birthdate: 1956-09-23
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
Couldn't see the pics you posted. But I did see them in your photo album. Looks great!
 
Logged Logged  
 
  The administrator has disabled public write access.
#275229
Curt (Moderator)
Never to old to ride!
Moderator
Posts: 17142
graphgraph
User Offline Click here to see the profile of this user
Gender: Male BlackIce
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
Really nice job. Gonna look great.
 
Logged Logged  
 
My Site

Black Ice is Shiny, Black Ice is Deadly, Ya Wanna Ride My BlackIce?
  The administrator has disabled public write access.
#275230
theGRINDER (User)
NO REGRETS!
Platinum Boarder
Posts: 2837
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Birthdate: 1969-09-13
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
Rich, that looks awesome! you did a great job on that... I am getting ready to paint my bike and I was thinking about making my own tank extension... but that looks really nice... what make is it? I know ya got it on ebay... I thought you may know... thanks...
 
Logged Logged  
 
http://api.viglink.com/api/click?format=go&key=9b4efad421c8b103b2c94b796db973b0&loc=http%3A%2F% 2Froadstarclinic.com%2Fcomponent%2Foption%2Ccom_primezilla%2Fpage%2Cread%2Fbox%2Cin%2Fmsgid%2C83871% 2FItemid%2C194%2F&subId=fd9e9391f99c39645438a8d5406628dd&v=1&libid=1351562468615&out=http%3A%2F% 2Fi1144.photobucket.com%2Falbum
  The administrator has disabled public write access.
#275234
Yamadog06 (User)
Fresh Boarder
Posts: 68
graphgraph
User Offline Click here to see the profile of this user
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
Excellent work. I'm impressed
 
Logged Logged  
  The administrator has disabled public write access.
#275236
B L U E (User)
~ The Punisher ~
Platinum Boarder
Posts: 2175
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Birthdate: 1955-00-00
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
What's really going on down there Rich, Just when I thought you couldn't make your Roadstar any more Badass looking, You go to Ebay and buy a tank Extension, Spill the rest of your project to me...
 
Logged Logged  
 
{My Fuel-Injected 08 BAD BOY}

Ride what you Like, But Like what you Ride ~~Dino~~
  The administrator has disabled public write access.
#275246
TampaSVT (User)
Life is hard. It's harder if yer' stupid(J.Wayne)
Platinum Boarder
Posts: 5065
graphgraph
User Offline Click here to see the profile of this user
Birthdate: 1965-07-03
Re:2 4 Years ago  
blue v twin wrote:
What's really going on down there Rich, Just when I thought you couldn't make your Roadstar any more Badass looking, You go to Ebay and buy a tank Extension, Spill the rest of your project to me...

Now, what fun would that be...

Grinder:
I'm pretty sure it's from www.sscustomcycle.com I see something very similar in the VStar BodyShop section. They're like $195.00, so the deal on Ebay was a steal...

Thanks for the kind comments, guys. I think it turned out pretty good for an amateur...


Rich
 
Logged Logged  
 

2008 Road Star
Tricky Air Ride(remote controlled)
6-degree Raked Front-end
Ape Hangers Internal Wiring
RoadHouse Dooleys
Featured in V-Twin Magazine, August 2012

Online Photo Album
  The administrator has disabled public write access.
#275252
theGRINDER (User)
NO REGRETS!
Platinum Boarder
Posts: 2837
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Birthdate: 1969-09-13
Re:2 4 Years ago  
dangitman... looks like i will be making my own if i want one...
 
Logged Logged  
 
http://api.viglink.com/api/click?format=go&key=9b4efad421c8b103b2c94b796db973b0&loc=http%3A%2F% 2Froadstarclinic.com%2Fcomponent%2Foption%2Ccom_primezilla%2Fpage%2Cread%2Fbox%2Cin%2Fmsgid%2C83871% 2FItemid%2C194%2F&subId=fd9e9391f99c39645438a8d5406628dd&v=1&libid=1351562468615&out=http%3A%2F% 2Fi1144.photobucket.com%2Falbum
  The administrator has disabled public write access.
#275262
Mr_Shamrock (User)
Platinum Boarder
Posts: 5001
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Location: Greenville, SC Birthdate: 1974-10-24
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
Looks fantastic man! You did a great job and your right, it looks like it came that way. Thanks for the pictures!
 
Logged Logged  
  The administrator has disabled public write access.
#275266
Inubus (User)
Gold Boarder
Posts: 758
graphgraph
User Offline Click here to see the profile of this user
Gender: Male Location: Skiatook, ok Birthdate: 1983-04-08
Re:2" Fuel Tank Extension - Step By Step 4 Years ago  
some really good work cant wait to see it finished and on the bike!
 
Logged Logged  
  The administrator has disabled public write access.
Go to top Post Reply
Powered by FireBoardget the latest posts directly to your desktop
...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... ...................................................................... -->
New Forum Posts




The Road Star Clinic is a collaborative community of riders who archive and publish user contributed technical data about Yamaha Road Star motorcycles.

We also sponsor the creation and support of other community websites similar to our own. Inquiries about availability of a website for your community can be submitted to us via any "Contact Us" option on the Clinic.

Copyright 2003-2007 Road Star Clinic and its respective authors. Road Star Clinic is sponsored by the folks at MLSHomeQuest.com.