DIY Network

'48 Indian Motorcycle: Fuel Tank Restoration, Interior Cleaning Chris custom fashions a jig to hold the vintage fuel tank securely during the restoraiton process. From "Classic Rides" episode DCLR-304

Once our tanks were cleaned up, we discovered that the interiors were in pretty bad shape. There is no way an adequate cleaning could be accomplished by working through the filler holes, so our only option is to cut the tanks open and then re-weld them together.

Chris creates a custom jig to hold the tanks secure during this phase of the restoration.

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Materials/tools:

original Indian fuel tanks
steel pieces for jig
air compressor
cut-off wheel
belt sander
wire brushes
scrapers
parts washer sink
brake cleaner
safety gear

Safety Alert: The first step in doing any kind of metal cutting is to put on the appropriate safety gear. In this case its gloves, eye protection and a heavy shirt with long sleeves wouldn't be bad idea.

Figure A

Instructions:

• Secure the tank with the inner, flat panel facing up.

• Using the cut-off wheel, make three cuts forming the shape of a triangle along the seams of the inner panel (figure A). When the cuts are complete the panel can be lifted out.

• With the inner panel removed, it's easy to access the interior of the tanks. Place the tanks in the parts washer sink allow the washer fluid to soak the interior for a couple of minutes. If a parts washer is not available, spraying generous amounts of brake cleaner into the tanks will also work.
  

  Figure B

• A jig is needed to hold the tanks during the cleaning process. Chris uses four pieces of angled steel to create a custom jig (figure B) that will support the tanks and allow them to hold their shape as they're being cleaned.

• Chris smoothes the edges of the jig using a belt sander. The jig components are then tack-welded together.

• Once the jig is complete, Chris carefully fits the tank into it (figure C)

• The tanks are cleaned using the parts washer. The washer fluid is a petroleum distillate that breaks down oil and old fuel residue.
  

  Figure C

• Once the interior is soaked, go to work with the scrapers and wire brush. Scrape and brush the interior until all the dirt, grime, and scale is removed.

  Safety Alert: Be sure to wear gloves to protect your skin when working with parts-washer fluid.

• Once everything it removed run the washer fluid or brake cleaner into the tanks once again and then allow them to drain.

• Remove the tanks from the parts washer and allow them to dry.

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