DIY Network

'48 Indian Motorcycle: Fuel Tank Restoration, Reassembly Chris Matthews reassembles the '48 Indian's fuel tank with some help from a MIG welder. From "Classic Rides" episode DCLR-304

Chris prepares the sand-blasted fuel tank, held securely in the custom jig, for cleaning and refurbishing.

With the fuel tanks cleaned out, it's not time to put them back together. Since this portion of the project involves welding, it's critical that we be sure that the parts are completely dry and free of any brake cleaner or parts-washing fluid.

Materials/Tools:

original Indian fuel tanks
custom tank-jig
mig welder
magnetic clamps
welding helmet

Safety Alert: Never weld without first putting on a welding helmet with eye protection. Looking directly into welding arc without eye protection can cause eye damage and blindness.

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	Figure A
	Figure B

Steps:

• Using the et the tank down on a flat surface, with the inner panel facing up.

• Using the magnetic clamps, set the inner panel piece that had been cut out in place and secure it.

• The MIG welder use used to weld the panel piece in place (figures A and B). It's important though, to not allow too much heat to build up in the metal. This could cause warping which will affect the final fitment. A good technique to prevent this is skip welding.

• To do this you would lay down a weld that is 1/2 inch to 1 inch long, skip a few inches and then weld another 1/2 inch to an inch. Repeat this process until you've reached the end of the area to be joined. Once the metal has cooled, you can then go back and repeat the process, filling in the areas that were skipped.

• Continue with this process until the seam is completely filled. Allow the tanks to cool one final time and we are ready for leading.

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