diy's d.i.y. fuel tank

diyRdie · 12-10-2019, 08:39 PM

Well, as some of you may remember. I have a 2017 magician.
ORIGINALLY POSTED HERE
The biggest problem on this bike was the fuel tank.it would develop leaks at the seam that joins the 2 halves. I tried patching it with glues and putty's. I bronze braised the whole seam. I even paid $50for an epoxy tank sealer. Not to mention. All the time spent on the problem. Q9 wasn't helping me at all of course. Txpowersoprts wanted like $90. I don't bleeping think so. I dont think all magicians have junk tanks. My best friend has a magician we ordered from same place on same day and they were delivered 2 days apart with vin numbers only 8 numbers off! Anyhow his tank is fine.
So I had built this fuel tank to get me through....

It got me through the last few months but a better solution was needed. So I started looking around to see what I could find to use. I am lucky to live near miles and miles of 4x4 trails to ride and at one certain point some human scum has began to use it as they're personal dump. Low and behold I found this.....

After two weeks of not much mental planning this is what happend..

Cut handles and valve off, put bolt through valve hole and weld shut. Take big hammer and negotiate into shape that resembles a fuel tank...

Drill hole for a brass hose barb and aluminum braise it in.

Find an old fuel tank to be a donor for a filler and cap..

Get it..

Braise it to new tank

Weld a mount on the front to use stock bolt hole and weld tab on top back end to hold the tie down straps..

Braise in threaded things for fuel level sight...

Grind paint off. (Should have done this first) and make everything smooth..

Spend a day and a half painting

Cut an old mower tire down to be a pad under the tank..

A few of them things..

And boom!

It holds almost 3gal and the stock magician tank only holds 1.8 I think.

Well thanks for checking it out. This was a fun build, but now I need to find another project...

12-10-2019, 08:39 PM	#1
diyRdie Join Date: May 2019 Location: Rockford, IL Posts: 98	diy's d.i.y. fuel tank Well, as some of you may remember. I have a 2017 magician. ORIGINALLY POSTED HERE The biggest problem on this bike was the fuel tank.it would develop leaks at the seam that joins the 2 halves. I tried patching it with glues and putty's. I bronze braised the whole seam. I even paid $50for an epoxy tank sealer. Not to mention. All the time spent on the problem. Q9 wasn't helping me at all of course. Txpowersoprts wanted like $90. I don't bleeping think so. I dont think all magicians have junk tanks. My best friend has a magician we ordered from same place on same day and they were delivered 2 days apart with vin numbers only 8 numbers off! Anyhow his tank is fine. So I had built this fuel tank to get me through.... It got me through the last few months but a better solution was needed. So I started looking around to see what I could find to use. I am lucky to live near miles and miles of 4x4 trails to ride and at one certain point some human scum has began to use it as they're personal dump. Low and behold I found this..... After two weeks of not much mental planning this is what happend.. Cut handles and valve off, put bolt through valve hole and weld shut. Take big hammer and negotiate into shape that resembles a fuel tank... Drill hole for a brass hose barb and aluminum braise it in. Find an old fuel tank to be a donor for a filler and cap.. Get it.. Braise it to new tank Weld a mount on the front to use stock bolt hole and weld tab on top back end to hold the tie down straps.. Braise in threaded things for fuel level sight... Grind paint off. (Should have done this first) and make everything smooth.. Spend a day and a half painting Cut an old mower tire down to be a pad under the tank.. A few of them things.. And boom! It holds almost 3gal and the stock magician tank only holds 1.8 I think. Well thanks for checking it out. This was a fun build, but now I need to find another project... __________________ Good judgment comes from experience, and often experience comes from bad judgment. MY BIKE'S THREAD
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