desert tank for kx 250 hybrid?

[mar67655]

IM thinking of swaping in a k5 motor into my 2002 kx 250 was wondering if anybody has used a desert tank for this conversion i trail ride a desert tank if i can use one would be great thanks for the help

[gwcrim]

I'd think you'll just have to modify a regular high capacity tank.  That's my plan.

[KXcam22]

I have heard of people plastic welding the bottom of the tank to modify it to clear the top of the motor.  Perhaps you could cut the bottom of a desert tank and weld it back together. Cam.

[gwcrim]

Can't you just use a heat gun to soften the plastic and sort of bend it to fit?  Or is an over sized tank just toooo big for that?

[USMC 500]

You won't know until you try to fit eveything together.  You might be able to heat the tank and make it fit.  You might have to put on a stock tank.  You might be able to have an aluminum tank fabricated to fit.  You might even find that everything will go together perfectly the first time without having to modify anything.   

[sintax]

yea, this is on my "to do" list of things to try once i get my bike fully running. From the pics i've seen this will likely be a challenge, but since i dont have a desert tank i have not been able to try it out. I'll be borrowing one from a friend eventually to check the fit.

I would love to hear about the results others have though.

[KXer]

I am 90% completed with my K5 swap into a 01 KX250 frame.  I used the heat gun/ BFH (big fing hammer) method.  I ended up burning a hole into the desert tank, but it is rather easy to heat up the surrounding areas to "Weld" it back together.  On my 3.1 or 3.2 IMS desert tank, you have to massage 3 places:
both sides where it hugs the head, and then right above the spark plug you have to completely manipulate that area to get it to fit.  I have to put the tank under the heat gun again to get it to completely clear the shorty plug I'm using ~ but I'm close.

[gwcrim]

On a related idea........ is there a petcock that can fit the stock 250 tank that would put in a reserve? 

At least you'd have some advance notice that you need gas NOW.

[racedezertkx5]

dc concepts used to make one out of a composite material like carbon fiber but i dont beleive he is in buisness anymore.aluminum might be your best bet