|After removing the bottom of the old King Sportster,
removing the aircraft-style fuelcap, welding shut the hole left
by the old fuelcap, drilling a new hole that is smaller and more
to the front of the tank and welding a bayonet from a donor-tank
into a section of pipe to get a flush-mount, this week we completed
the gascap and mounted it in the tank.
|From a solid lump of steel we machined a press-fit
for the inside of the stock gascap, leaving a small airgap inside
so the vent will still work. No matter how powerfull your engine
is, closing that small 1mm breather hole in the gascap will turn
it into an immovable object...We machined the flush-mounted bayonet
so that it was exactly the same hight as the top of the gascap,
and then added a stepped fit to the weld area.
|Starting with 4 small spotwelds, Aad carefully
added welds in a criss-cross pattern to avoid too much heat so
the tank wouldn't warp. Then it was time for the grinder again
to clean up the welds, this is all we had time for this week,
next week we will add the rib over the tank and the gascap, without
that it would be very hard to open!