Making Motorcycle Gas Tanks - Part 2
HTML-код
- Опубликовано: 7 фев 2025
- This video shows how to make a curvy custom motorcycle gas tank, from aluminum!
You can help me create new videos by becoming a Patreon. Here’s the link:
/ roncovell
I have lots more RUclips videos, and here's a link to my website - which lists 20 full-length videos you can rent, stream, or download, plus the Covell line of fine-quality metalworking tools: covell.biz/
You can see the great Covell shirts, cups, and stickers here: rons-store-10....
Special thanks to all my sponsors on Patreon: Trevor Kam, Jonathan K, William Longyard, Dominic Peterson, Jonathan Hodgins, Ben Hengst, Bill Kerr, Christopher Culbreath, Wes Fullenwider, Gordon Stipe, Teemu Vartiainen, Matt Maurin, Terry Doss, Clifton Ballad, R Rickel, Donald Summers Sr., Luke Hares, Matthew Schumacher, Nicolas Audouard, Todd Henry, DHFG, Corey Brabant, Nick Rosati, and Don Cober.
![[A's BMW vol.5] Aluminum fuel tank making process.アルミタンクの製作 BMW R100RS](http://i.ytimg.com/vi/jphGVSA0VD4/mqdefault.jpg)
![Seungmin "그렇게, 천천히, 우리(As we are)" | [Stray Kids : SKZ-PLAYER]](http://i.ytimg.com/vi/kAzmhLHePqU/mqdefault.jpg)
![BLACK BAG - Official Trailer [HD] - Only in Theaters March 14](http://i.ytimg.com/vi/Du0Xp8WX_7I/mqdefault.jpg)
![Felix "Unfair" | [Stray Kids : SKZ-PLAYER]](http://i.ytimg.com/vi/Oswujxm2Ag0/mqdefault.jpg)
I absolutely love how he makes this look easy, and how smoothly the entire process went.
Though I would add that I've been around long enough to know that this man is an artist, and that his craft is the product of many years of applied craftsmanship and refinement.
Thank you so much for the kind words!
Do you take also custom orders for making a tank?
No, I'm semi-retired now. One of the best in the US is Evan Wilcox - www.evanwilcoxmetal.com/
every time you upload a video I'm in shock of how simple you make it look. you are like the bob ross of metal crafting! hats of to you sir.
I appreciate your comments. Doing this work does get simpler with lots of practice!
I worked for McDonnell Douglas/Boeing and saw a number of mass produced contoured rounded structures ....what they used were dies and molds and Bag Press technology ...they put in the form and the sheet metal and then a hydraulic bag forced the metal into the exact shape ....way faster than on thi video but not a bit better looking! Not to mention the tool and die hours that went into such not to mention the major expense of a bag press operation! This guy is doing what big corporations pay entire crews to do in high buck facilities!
Dougie Quick - the process you describe is called 'hydroforming' and it is still used for many industrial fabrications. It requires a huge investment in tooling, but once that is done, the parts can be made very efficiently. The processes I use are better suited for one-off parts, or small production runs.
best job ever in RUclips, thanks for sharing your art.
Greetings from Spain!!!
Thank you so much! Be sure to check out some of my other videos on RUclips - you may find more to like!
Was thinking about how to make a seat pan for a small moped seat, and this video shows that it's more than possible to make it work. Thank you!
Great - I'm glad you got some inspiration from the video!
Ron is indeed a master of his craft. That gas tank looks outstanding.
Thank you!
Great Stuff - I had a tank made by a very old Bill Lyta in England and my greatest regret is I didn't offer myself as an apprentice. He was amazing - he made the tank in less than a day and had a minimal amount of equipment. I have the same regret for not engaging 'Mike The Pipe' Hawthorne who hand bent the exhaust pipe for me special. He bent a perfect radius with just a gas torch - no sand or forms. Again awesome information and thanks so much.
Those sound like some very talented people, indeed. Fortunately, a lot of people are sharing their talents on RUclips now!
@@RonCovell I found the invoice! The tank was a 125 UK pounds . His company name was Lyta - his actual name was Bill G. Hichison. I remember that he had a good selection of hammers, three oak tree stumps with different radius bowls cut into them as well as a leather bag and a really large cast iron English wheel. Watching him go from a bag of marbles to a really smooth piece of metal in half an hour was pretty awe inspiring. Sadly he was pre-internet and a lot of his tricks no doubt went with him to the grave. Mike The Pipe made the vast majority of British F1 exhaust manifolds - this is before cnc mandrel bending machines were ubiquitous.Thanks for passing on what no doubt is decades in the making.
I'd say you got a bargain! It is sad when such talented people aren't able to pass their skill and knowledge along to others. That's exactly what has made RUclips so big (plus all the cat videos)!
@@RonCovell At the time it didn't seem a bargain - in fact it was every penny I had! In retrospect it was an incredible deal. I think you should be looking at a business model like Patreon. Glad you hooked up with TOT - amazing content and production values with an incredible sense of humour. You might also talk to AVE - he seems to have figured out the Patreon biz model as best as anyone.
I've learned so much from you over the years. Thank you man.
I'm glad you have enjoyed the videos. There will be more to come!
Supreme work considered art in my eyes
Thanks for the high compliment!
It is so great that you share your vast wealth of knowledge with all of us so hungry to learn. Thank you so much
I'm so glad you enjoyed it!
Interesting. I did my apprenticeship in sheet metal and did a lot of shaping such as this with Aluminium. We used soap to check the annealing temp. We only used the steel wheels for final finishing. The shape work was all done with a rubber wheel and another machine we used was called a bumper. It was two long arms with a 1 inch ball in the top arm and a rubber pad in the bottom arm. It was a mechanical hammer and would stretch the metal to raise up areas. We used wood mallets over a dolly to shrink the metal by creating pleats that were then smoothed out. It was hard work and took many years to get as good as the old guys who taught me.
You were doing the 'real deal', indeed!
How many times can I comment on your work? It's not only excellent welding but extraordinary metalworking!!
Thank you very much!
Lovely videos Ron, both parts. Really useful and really enjoyed them, thanks a lot.
Glad you like them!
Always a great experience watching your videos. I have several. Hope to see you in August at the Louisville. KY NSRA. Always a pleasure to speak to a metal master like yourself.
Thank you so much. I'm not sure I'm going to Louisville this year, but come up and say 'Hi' if you see me!
Great video Ron, you are an artist. Amazing!!
Thank you very much!
You too :)
WOW - Thats the most highly advanced hair i've ever seen and the tank building is pretty good too
That video was shot about 15 years ago, and my hair is MUCH more advanced today (thinner and grayer) as you'll see in my more recent RUclips videos! Glad you liked the tank building, too.
That file technique and the gunlike tool are so cool
Glad you think so!
Ron, I have this video. Helped me make several gas tanks. You are a fantastic teacher. Thanks for sharing your knowledge. Actually, I think you may have used one of my portable English wheels for a class at Tucci hot rods. Take care, and keep the videos coming.
Garth, thanks so much for the use of your machine at Tucci's, and I'm glad you have enjoyed my videos.!
I dont even understand how there is dislikes on this video, i thought it was awesome and very informative!
Uncle Weirdo - You just can't predict how some people will react to stuff, but I'm very glad that YOU liked it, and took the time to comment!
Just exceptional work Ron.
Thank you so much!
Thanks for sharing this informative and useful video
I'm very glad you enjoyed the video, and took the time co comment!
Best tv show I've watched all Pandemic. thanks!
Wow - that's very high praise, indeed. Thank you very much!
Look a master craftsman at work.
Thanks for the kind words!
True craftsmanship.
Glad you liked it!
Excellent Ron ! You are te master of metal shaping . Grettings from Argentina.
Guillermo - thanks for checking in, and leaving a comment. I do not have a lot of viewers in Argentina!
I your first fanatic ! I see yours videos from the channel begin. If ona day I come to USA , I visit you!
I look forward to meeting you!
Ron! Good to see another awesome video! I've always admired your sheet metal skills
Thanks for your continued interest. There will be more videos in the future!
Love watching these vids from Ron. Literally my inspiration for what I do
I hope that inspiration leads you to do some good work!
I don't have much experience with oxy-fuel welding. I have an everlast welder. Can I tig weld tanks like this?
Yes, you can. I TIG welded the tunnel and the bottom seams in this tank.
Nathan Nicholas Garcia 52 Performance Fishing et
snoopy doggy est;
Ron... I like your Level of Perfection,!!
Thank you so much!
best hand building i've seen
respect from algeria
Thank you very much!
You sir are a master and inspiration!
Thank you so much!
Master of sheetmetal👏👏👏Greetings from Göttingen🇩🇪
Thanks for the nice comment! With any luck, I may be teaching a workshop in Germany later this year.
That would be a super service for the german community . Stay healthy my friend!
I had a great response with my first workshop in Germany, in 2018.
Wow I wish I could move a hammer that fast. you got mad skills. Your videos are very helpfull
Glad you like them!
This is an art man.. so simple you doing that.. slap hammer ???? It's cool
I'm so glad you enjoyed the video!
Ron, You're a master!
Elias Akel - Thank you for the kind words!
Holy shit!! Thats an insane form of art! Hats off!!
I'm very glad you enjoyed this video.
I might be able to form something similar to the tank out of clay. 😁 But I am so impressed about shaping a completely flat piece of metal to all these curves. I've seen Ron at SEMA 2016 showing some very interesting streching and shrinking basics - I love this kind of art.
I'm glad you enjoyed the video. You know, lots of people do model parts from clay, and there are several methods of producing a composite or metal part from a clay model.
Hello Ron, thanks a lot for your reply. I've seen designers using clay to find perfect lines in prototyping. Knowing about that it becomes more impressive to see you using a 2D cardboard as a base. 😉👍 I hope to see you at SEMA 2017, Greetings, TOBi
I'll be demonstrating in the Trick Tools booth again at SEMA this year. Come by and say hello!
Every time I am a little scared about these 20hour flights - but the SEMA show is worth it every year. 😉 I am looking forward to watch you demonstrating at the booth and I'll to say hello. Have a good time bending and rolling - see you at SEMA 2017. 👍
Vous êtes un artiste .
Merci beaucoup!
brilliant works brother congratulation to you
Thank you!
wow fell down the rabit hole of you tube. man this was awesome to watch
Glad you liked it!
I guess the biggest weak point in the proccess is the weld due to the fact so much is grinded off and it can weep petrol if not dome perfectly. So important I guess to 100% know your welding techniques and to start off with clean metal. It is not even possible to weld a good bead on the inside due to access and then a decorative one on the outside for filling and grinding and cosmetic purposes. I suppose you could fill your tank with a tank sealer which I suppose you are going to need anyway if you are using mildsteal as the petrol will corrode the metal over time anyway. Brilliant skills and it shows taking one step at a time in life and having persistence will get you there. Of course with this technique practice makes perfect.
Thanks for watching, and your points are well taken. Petrol itself does not corrode steel tanks, but it often collects moisture (condensation), which can cause rusting.
A long time since I saw someone oxy acetylene alu. Easy to ruin without practice. Surprised you don’t experience distortion though your experience decided the tack distance. You’re very sure that these welds are still homogenous after ‘metal treatment’ (heavy grinding etc) - quite a potential mishap if they are weak at any point - (collision...). Really nice work you showed - quite encouraging :-) thx
I'm glad you enjoyed seeing this!
Some serious skill here, hope we won't lose this to robots.
While robots have their place in the world, there will always be a need for humans to design things, and to do custom fabrication.
Fantastico, splendido lavoro!!
Grazie mille!
such a professional hand work.. nice
Thank you so much!
Outrageous! Amazed! WOW!
Dougie Quick - I'm so glad you liked it!
Lindo trabalho, parabéns
Obrigado!
Looks like magic...
It's really not magic - just applied technology!
@@RonCovell Maybe...when it comes to the most universal of machines - man, the process is little different from magic, because the details are first born in the mind of the master ... Man - it sounds proudly, and the master is more than a man, as my teacher in a technical college said .
Excellent skills
Thanks for watching, and commenting! I currently have 44 RUclips videos, so please check out some of the others.
Rare skill...almost forgotten these days...the English wheel, the hammers, sand bags etc.
From my point of view, there are more people learning these skills now than ever before! I think RUclips and television have a LOT to do with this fact!
Amazing... best regard from Top VGM klasik custom from Indonesia
I'm very glad you enjoyed it!
Now that is art...
Thanks - that's high praise, indeed!
Spectacular your art, congratulations.
Thanks!
Is it necessary to quench the aluminum after heating to aneal?
No - quenching is not necessary when annealing aluminum.
The best work in the world!
Thanks for the wonderful compliment!
Gotta make sure you emphasize using the proper threaded bung, for the petcock.
Yes, that's a very good point! This RUclips video is a much-shortened version of a 2 hr 45-minute DVD, and I do go into the details of the bungs in that program.
I will be very glad if you could tell me which thickness of the metal sheet is best for making a fuel tank
I used 2mm aluminum for this tank.
@@RonCovell thanks for replying
Sir"
How to do that 4:13
You're so faster 🤣😆
I guess you are remarking about the 'speeded-up' hammering? Yes, it's all a trick of video editing, but I have learned that most people like it when I speed up the repetitive parts of videos.
OMG this is unreal!
Glad you like it!
Hey Ron, great to see you back & being beautifully creative!!! BTW, did you ever get that young lady from TX (Rachel Deschner) in as a student of yours or recommended to someone who can help further her metal crafting skills? It's already been a year & I haven't checked on her, either. She's so very talented, just needing more of what she has, and tools, tools, tools... Of course, there is that attention span thing of being young with broadly varied interests. Hahaha... Keep up the great works man, always an inspiration! Always looking forward to more from you, too. 😎
Zeek, I did reach out to Rachael, but I guess she had so many opportunities that she never followed up with me. She certainly is a talented young woman, and I think her future is bright. Glad you liked the newly-posted video!
Yep, I peeked at her Facebook page & she hasn't posted anything since April, looks like graduation pictures. Busy, busy busy being young. 😉 I think I was that, a long time ago...
really good 😊😊😊
Thank you - I looked at your RUclips videos, and you are doing very nice work!
This guy's awfully good. Lots of practice behind making the process look so easy tho.
Thanks for watching, and commenting! Yes, I have practiced a lot, but everyone starts from the same point!
Thanks 👍😊
No problem 😊
💯😘
we love you Ron!
Adam - Wow - you are the first to comment! Thanks for all the support. It means more than you know!
He's spot on , I really like your vids , even though they are short they still help germinate ideas for making things
P.S. you may want to put a link to your shop in the description below the video as it will make it easier to go to your site directly
Cheers
Allan - thanks for your comments. I had never thought to list my website in the video description. That's a fabulous idea, and I have added it to ALL of my RUclips videos! Let me know anytime you have another idea like that.
God bless You Genius : ), I love Your movies . Regards from Poland.
Thanks so much for your wonderful comment!
Thanks for show Your craft Master Ron : ).
Great Job
Thanks for watching, and for commenting!
true craftman this is awsome wish i could do this
I encourage you to try your hand at it. You might surprise yourself!
i dont have the proper tools or teacher haha but who knows maybe in the future
After seeing this, I don't think I will attempt to make an aluminum tank any time soon. Thanks.
Gosh - I had no intention of intimidating anyone. I don't know if you have seen my video on making a steel tank, but that one is easier (even if you used aluminum instead of steel) because it doesn't have as many curvy shapes: ruclips.net/video/UmQ_V5ihmZY/видео.html
Very impressive sir.👍
I'm glad you enjoyed the video!
Incredible.
Sounds like you enjoyed the video!
The bob ross of fabrication
I take that as a huge compliment!
Which DVD would best suit a sheet metal newbie? All of the DVD's on your site look so tempting.
Matthew - as you have seen, I have quite a selection to choose from, so it really depends on what sort of work you want to learn to do. Most people who are working on a hobby vehicle - car of motorcycle - will be working with steel, and they will be filling holes, fixing dents, repairing rust, and making patch panels. My video 'Basic Techniques for Working with Steel' covers these topics, and more. Send me an email at covell@cruzio.com if you have more questions.
Curious as to if you can smooth with a pullmax instead of a English wheel?
You can certainly do some smoothing with a Pullmax, but in general a power hammer, planishing hammer, or an English wheel are more efficient for smoothing.
Love these videos
I'm so glad you enjoy them!
Amazing vídeo
Thank you so much, Andre!
One thing I've wondered for a long time is, how is gas supposed to get from one side of the tunnel to the other when its level gets down that low and you're in the middle of nowhere? Many bikes are too big and heavy to tip over to transfer it (and you can't tip a 4-wheeler easily).
Many gas tanks have a 'cross-over' tube that feeds gas from one side of the tank to the other. You can see pictures on this page:
www.dansmc.com/gastank.htm
That page seems to only mention 2-piece tanks having a cross-over. My KZ750B1 and Moto-4 225 have nothing to bring right sump gas to the petcock in the left sump of the 1-piece tank when running that low.
The crossover tube will work for single tanks, too - where the lower portion is divided into two sections by the tunnel. You would need to weld a barb fitting onto the lower section of each tank side, and connect the fittings with a small hose.
Nice job,thanks for share:-)
Thank you too!
Great content!
Thanks!
What is time frame to produce al that?????It's important to know time to product it in your shop!!!! You do good presentations for sure.
Great guy, great video. He has a voice somewhat similar to Mr. Rogers. :-)
Thanks so much!
@@RonCovell, You're welcome. I'm sure you've heard this a million times before but custom sheet metal work is becoming a lost art. (unless you're an HVAC guy) Everything is computer-controlled, punch, hydroformed, rotary mandrel-bent, etc. You're in to the RUclips thing and hopefully, young adults will be drawn to such a career because of the great example you set in your engaging videos.
Thanks for all that you do. It's an absolute pleasure to watch your videos.
Absolutely stunning work. Would it be possible to weld the bottom of the tank with the oxy-acetylene torch? If so, how would one flux the inner seam? Would you flux each edge before you fit it together? Thanks!
Yes, you could gas weld all of the seams. You certainly could brush some flux on the inside of the joint before welding. The flux needs to be washed off within a few hours, but it dissolves nicely in hot water. You can pour very hot water inside the tank and shake it around to remove the flux from inside the tank. I would repeat this a couple of times, since even a tiny speck of the flux can cause corrosion to form over time.
Awesome, thank you!
Beautiful
Thanks!
Were you welding, or were you brazing?
I was welding.
i've never seen it. but it kinda looks like an analogic tig welding. :) just kidding
nice
I need to get the video
Glad you liked it. Did you know that in addition to our DVDs, you can rent, stream, or download the videos?
covell.cinevee.com/making-motorcycle-gas-tanks
Any recommendations on aluminum alloy grades to start with? Do you leave the tank in an annealed state?
I prefer 3003 alloy. Even if the material is annealed, it develops sufficient strength by work hardening, and the domed shapes give it extra rigidity, also.
Great job... What kind of stick do you use to weld aluminium with your torch?!
The filler rod I use is 1100 alloy aluminum, 1/16-inch diameter (1.6mm).
@@RonCovell what kind of tungsten? Thanks in advance
Back when this video was made, I was still using 2% Thoriated tungsten. Currently, Ceriated, Lanthanated, and Rare Earth tungstens are better choices.
@@RonCovell man your awesome i stayed up all night watching these vids lol
I'm so glad you liked them! I'll be posting more videos soon, maybe even tomorrow!
Question: Is oxy welding aluminum welding or soldering?
Aluminum can be both welded and soldered. Welding is joining by melting two pieces together, and if filler rod is used, it is made from a material that melts at around the same temperature as the base metal. Soldering uses a material that melts BELOW the melting temperature of the base metal, and it joins pieces by surface bonding, rather than melting together.
@@RonCovell Thanks for clarifying that Ron. I should've paid more attention in class. lol
Do you ever create your tanks using a powertig welder?
I have used Miller welders exclusively for many years, and I am always delighted with their features and performance.
The Master.
Thank you so much!
.... SUPER !!!
I can cut the sheet metal with my powerplasma cutter easy enough but what if I don't have the powered hammer to form the curves?
Thousands of motorcycle gas tanks have been made by rough shaping with a mallet and sandbag, and smoothing with hammers and dollies. My DVD 'Shaping Aluminum with Hand Tools shows this in good detail, but I don't have a RUclips video of this process. The closest thing I could find is this one: ruclips.net/video/XQG67ezXWsE/видео.html
That's some very nice work there brother. Any chance you could make a 3/4 gal tank for me? I don't have the time it takes for a custom tank. I need it for a custom peddle chopper. I am working on the twin V engine. With a pattern I got from Germany. I might have time next year to make a tank, but I hope to be riding by fall. If you can, I would like the same shape of tank as this video. I would like to have it unfinished so when polished and shot with a translucent blue paint, it will look like blue chrome. To match the finders and frame. But I might do some ghost flames. If the House of Kolor can match the shade of blue I have in mind. And I am betting they can. The paint they make is like liquid heaven. I will be sure to credit your work if should I be published. I know a great deal of people would also like the small custom tanks. Could be a start of a new line of fast selling tanks, if the cost is right for a adult toy.. Anyway if yes hit me up, if your not wanting to help me out. No hard feelings you do make a very nice handmade tank. Far better the cheap made in China crap I see around town.
Crowley - I can envision what a polished aluminum tank would look like with translucent paint - it would be great! Thanks for the nice offer, but I don't do work for customers any more.
thank you.
excellent.
I'm very glad you liked it!
RON ... BUEN VIDEO UNA PREGUNGA SOY DE PERÚ ...¿ QUÉ ÉS LA PASTA Q LE ECHAS POR DENTRO ANTES DE SOLDARLO.??.GRACIAS
Creo que se está refiriendo al flujo de soldadura de aluminio; puede verlo aquí: www.fournierenterprises.com/m3/GWF08--amco-22-aluminum-gas-welding-flux-8-oz-gwf08. html
Great job !!!! How many machines I would have to buy for such a projects ?
I'd say the minimum requirement would be a mallet and sandbag, a couple of hammers and dollies, some metal shears, and welding equipment.
Very nice! I have two questions though...
1) How much material are you taking off with the draw file, during the process of leveling the surface?
2) I noticed you hammered the OA-welded bead flat, but then sanded the TIG-welded bead flat. Is there any particular reason? It didn't look like there was that much more bead with the TIG weld, but maybe that's it?
Thanks Ron!
Tom B - Good questions!
1. The material I used was .080" aluminum, and I probably removed about .008" with the filing.
2. Gas welds are softer than TIG welds, and are usually lower-profile, so it is often feasible to hammer (planish) them flat. Since the TIG welds are harder, and often larger, I usually just sand them flat, although they can be planished to a certain degree. If I do plan to planish a TIG weld, I usually sand or file the outside flush, and then hammer (or wheel) the weld until it becomes flush on the inside.
OK, thanks. I suppose that if the TIG weld were to be planished, it might even fracture due to being harder...unless it was normalized first.
I would have thought that you were taking off more than 0.008" though, to be honest. But with 0.080" material thickness, I guess you've got some to give without a problem.
Súper cool thanks
I'm very glad you liked it!
Excelent!! Verry nice
I'm so glad you enjoyed it! I plan to post some new videos soon.
отличная работа!
Благодаря!
Congratulation!
Thank you so much!
По Discovery показали как Вы делаете бензобак на мотоцикл. Отличная работа!
Отлично. Я рад, что вам понравилось!