another perfectly good motorcycle ruined.......

Monday, 17 January 2011


so, after the big weekend clean-up and shed re-organistion, it was back to work on the sporty, the original filler on the fuel tank is pressed into an apperture in the top and welded into position, the weld leaves a ridge which has to be carefully removed with a dremel and carbide bit to allow the quick-filler to sit flush, the original welded filler has to be cut back to give enough room for the mounting screws which sit, [as you can see in the second photo], very close to the edge of the hole, it takes a bit of work to grind to shape with a small stone wheel in the drill as the metal is really too thin to file for fear of denting the tank, quick rub up with emery to finish and drill the mounting holes, [i used a centre drill to pilot the holes and then a 4mm hss bit and just gently clean up with a round file to give clearance for the screws] if you look carefully at photo 2 you can see where the original filler was welded into the tank, you have to be really careful when drilling the new mounting holes in case the drill 'wanders' into the groove and throws your centres out, bit of a squeeky bum moment but i reckon the result is worth it.

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