You can reshape your tank using boiling water. I boiled water in my wife's two soup pots and then poured it in the stainless steel sink in our utility room. I put the tank minus the petcock (I built a little aluminum plate and used a bit of floor mat to block the opening off) in the water for 2-3 minutes to heat up. It becomes very easy to shape, but I would use a tire spoon or something metal to push on it because it was a bit too hot to use your hands. The boiled water will cool off pretty quickly, so I would have it marked and a general idea of how much you need before you start. Once you like where it is, run some cold tap water over it, and you're done. It's actually very easy and seemed really safe. Just like forming you sports mouthpiece.
As far as the radiator mounts, I just welded up the holes and then marked a spot forward about 3/8" and drilled and tapped it. I made new radiator braces out of aluminum to keep the radiators pushed forward just a little bit. Don't push them forward too much or the hoses will kink.
Here's a link on how to post photos using photobucket. I can't wait to see pics; it sounds like a very interesting build!
http://www.kxriders.com/forums/index.php/topic,10040.0.html
Tried molding the tank with water tonight. I didnt get it to budge... the bottom of the tank hits the water spigot on the head.
this suzuki tank is pretty dam thick right there. I didnt get anywhere with my harbor freight heat gun either, but I'm afraid of burning the tank with the heat gun. I havent found any detailed tank molding tips on here.
I've got to figure something out, or just pay to fab a one off 2tall kit.
Used tanks are cheap enough, and Clarke's website says they will make a new one in black.
Here goes... gonna heat the crap out of it and if it fails get a new clarke and rip off the 2tall idea.
I like the new 2tall ripoff idea the best but dam that'd be expensive.