In preparation to ride to Alaska and back, I decided to make a larger gas tank for my Hawk. I bought a damaged tank for $100. I cut the tank in half horizontally. Since I had located a vented gas cap, I decided to plug the vent and overflow tubes to make my job easier. My friend, Mike, welded a 4 inch band of steel between the two halves. I can now go at least 250 miles on a tank. The only problem that I encountered on the trip was a vapor build-up between the gas cap and my tank bag (I am in the process of making a spacer to place between the tank and my bag. Now I have a touring tank and a canyon tank. Total cost excluding labor was about $500.

 

Very nice. How did you cut it? Plasma?

 

Plasma? Way too fancy for me, used a 4 inch grinder.

 

That's pretty cool. Someone either here or on the VTR1000.org site did the exact same thing, but they only raised thier tank about 2-3" if I remember correctly.

Did you actually fill the tank with a liquid and see how much volume is inside, or is 7 gallons an educated guess?

 

That was me. Back in 2003 I also used a special alloy steel and phosphate treated it before and after welding, then cleaned and coated the interior with POR15 two times.

I was actually thinking of selling it as whereas old age and treachery trumps youth and exuberance, one's prostate limits range to the OEM fuel tank capacity mileage...

The vented gas gap I found (though did not buy), as the OEM vent is intact is made by Yoyodyne, and accordingly is pricey.

Honda Rapid Lock Tank Cap Silver