DIY Network

'48 Indian Motorcycle: Fuel Tank Restoration, Exterior Chris Matthews' restoration of the Indian's fuel tank includes a vintage metal repair technique known as leading. From "Classic Rides" episode DCLR-304

The 1948 Indian Chief, AFTER the complete restoration.

In this phase of our motorcycle restoration project, DIY's Classic Rides host Craig Reynolds and antique motorcycle expert Chris Matthews refurbish the fuel tank on our project bike, a 1948 Indian Chief.

In order to restore the fuel tanks on our 1948 Indian Chief, we're going to have to get a look inside to assess the tanks' condition. While we might get a relatively good idea just by looking in through the gas cap, the tanks will still need to be opened up to do any work.

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The restored fuel tanks

Project Overview

After initial inspection, Craig and Chris work together to do a full fuel-tank restoration on our 1948 Indian Chief. The old tank is sandblasted and then taken apart so they can clean and sandblast the interior of the tank.

Chris provides us a lesson on welding and on the practically lost art of leading a tank. There are only a few people left who actually still "lead" a tank.

Basic tools used throughout this phase of the restoration:

standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, etc.)
bike jack and stands
parts washer (or brake cleaner)
sand blasting cabinet
parts washer
brake cleaner
eye protection

Note: This is a summary of steps included in the restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

Important: Always dispose of automotive fluids (gasoline, antifreeze, motor oil, transmission fluid, power steering fluid, etc.) and other toxic substances responsibly. Most auto center offer recycling of automotive fluids.

	Figure A
	Figure B
	Figure C
	Figure D

Exterior Cleaning

The first step is to clean up the exterior of the tanks and remove any rust or existing body work.

Materials/tools:

sand blasting cabinet
air compressor
original Indian fuel tanks

Steps:

• With the tanks removed from the motorcycle, the deteriorated fuel that was left in the tank years ago needs to be completely removed. To do this, Chris removes the gas cap and hooks the tank up to the end of a tail pipe on an automobile. By piping car exhaust into the Indian's fuel tank (figures A and B), the volatile fuel vapors are evaporated, leaving the tank safe to work on.

• We need to assess the overall condition of the fuel tanks. The paint will have to be removed to discover if there's any rust, body-filler repair or other work done. We're fortunate enough to have a sand blasting cabinet, but if one is not available for our restoration, chemical paint striper, sand paper and a wire brush can be used to remove the old paint.

• Place the tank in the sand blasting cabinet. Open the valve for the compressed air.

• Turn on the vacuum on the cabinet.

• Using the sandblaster, remove all the old paint, dirt, and rust from the tanks (figure C). Insert your hands into the attached gloves and control the air and sand flow with the foot pedal.

• When all the old paint and rust is removed the tanks can be taken from the blasting cabinet and inspected (figure D).

Classic Rides DIY FYI: Sandblasting is also called bead blasting and is used to smooth, shape, and clean hard surfaces through small particles of sand or beads. The small particles hit the surface at a very high rate of speed. The effect is similar to using sandpaper, but the finish is more even. Sandblasting can also occur naturally through the wind if it is at a high enough speed. The artificial sandblasting process was patented by Benjamin Chew Tilghman on October 18, 1870.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Gaskets/Headers
James Gaskets
Website: www.jamesgaskets.com