gas tank ideas

[yeomans]

Yeomans, would your guy be willing to do a tank for me?  Can you put me in touch?

gwcrim heres the info I have for him

Baileys Plastic Fabrication Ltd.

His name is Chris Bailey, really nice and super knowledgeable about plastics.
email  baileysltd@ns.sympatico.ca
web site www.baileysplastic.com

Just let him know you've seen one of his tanks and explain to him thats what you're looking to have done.
He's a small local guy, so he'd probably be really surprised about someone calling from the U.S lol.

When I got mine done he told me it wouldn't be pretty, but it would hold. I also was told that I could get a sander out and sand some of the welded area down to smooth out the tank for looks if I was concerned.
Figure out how much tank you need cut off and mark it. The tank was cut on a bandsaw so the new piece of plastic could be a flat bottomed tank with grade towards the petcock.
Your petcock placement is key as well. If you need any better photos of my tank just let me know
 

[gwcrim]

Canada may be my only option. 

[yeomans]

Don't know if you were on suva's thread he had started ''k5 rebirth'' but the ims tanks are a much closer fit to start with then the Clarke tanks, they require way less modification.
I only found this out after I had modified my Clarke tank when I bought a used ims tank for my 250.
Had I have known this earlier I probably would have attempted the boiling water trick on the ims tank at home. I'm assuming you wouldn't also have to use a brand new tank doing it that way.
I could get you some pics later on this week once my frames back from powder coating if you'd like

[gwcrim]

I did read that thread.  I'll see what a Clarke tank looks like up close and personal soon. 

[gwcrim]

I put the word out on Facebook.  One of my son's pals is in welding at the vocational school.  He asked his teacher (who is a dirtbike guy) and I now have a plan.  I talked to him last night and he said he'd do it but wanted to research a bit first.  He also said that a new tank would be a good idea.   

Making progress!

[yeomans]

Nice,
Wished I could have done a tank in metal.
Don't have any friends who weld aluminum through, so it would cost too much to pay someone to do it.
Can't wait to see some pics of that bad boy.
True works style

[gwcrim]

I guess I should have been more specific.  He's going to cut and weld a plastic tank for me.  He recommended starting with a new one.

Aluminum would the da shizz.   

[Brute]

How big a tank are you looking to build? Attach a gallon or build a bigger tank, that is the question. 

[gwcrim]

I'm going to buy a new Clarke or IMS tank and cut the bottom for clearance.  The way that Yeomans did it.

[gwcrim]

As I'm putting this thing together, I'm wondering if I ought to cut the rear bracket boss off the head for added clearance.  I'll be using a Jfab head stay.

[sandblaster]

You might be able to pull that off but I wouldn't risk it....
Then again you can always re-weld and patch if there is a problem 

[gwcrim]

I dunno........ it would free up more than an inch of room.  Might have to take the sawzall to that hunk of aluminum.

[sandblaster]

I agree something needs to be done with that hunk of aluminum but over kill is better then snapping your frame rails after you just cleared that 100' quad jump 

[gwcrim]

In my case, it wont be used.  There's nothing to bolt it to.  I'll be using a Jfab head say that mounts at the front of the head.

[gwcrim]

Just talked to the guy at justgastanks.com.  IMS has a 3.7 gallon tank for the 2002 KX250.  I think I've seen one.  The extra capacity is up top.  Fugly as all heck but given A) the 500 sucks so much fuel and B) that I'll be cutting capacity off the bottom, I just may go that route.