Ever looked at your motorcycle and wished it reflected more of your unique style? Custom gas tanks are one of the most striking ways to transform your bike into a true personal statement. Whether you’re aiming for a sleek café racer look or bold custom art, knowing how to create or modify a gas tank unlocks endless possibilities.
In this article, you’ll discover practical steps, helpful tips, and expert insights to guide your custom motorcycle gas tank journey.
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How to Choose and Install Custom Motorcycle Gas Tanks
When you want your motorcycle to stand out from the crowd, upgrading to a custom gas tank is a bold and exciting step. Custom motorcycle gas tanks do more than just hold fuel—they set the tone for your bike’s style, improve its performance, and let your personality shine through every mile. Whether you own a chopper, bobber, café racer, or cruiser, understanding how to select, install, and care for a custom gas tank can make all the difference.
What Makes a Custom Motorcycle Gas Tank Special?
A custom motorcycle gas tank transforms the look, feel, and sometimes even the riding dynamics of your bike. Unlike factory-fitted tanks, which are designed for mass appeal and mass production, custom tanks are crafted with unique shapes, materials, and features tailored to individual tastes. Here are some standout aspects of custom gas tanks:
- Unique Designs: From classic teardrop shapes to angular vintage styles, you can pick a tank that matches your bike’s theme or your personal vibe.
- Materials and Finishes: Options range from polished aluminum to rugged steel, with finishes like raw, painted, or powder-coated.
- Fitment Options: Custom tanks can be made to bolt directly onto stock mounts or require bespoke fabrication for an even more personalized result.
Let’s dive into how you can select the right custom gas tank, the steps involved in installation, and the practicalities of making your motorcycle truly one-of-a-kind.
Choosing the Right Custom Gas Tank for Your Motorcycle
Selecting a custom gas tank isn’t just about picking out a design you like. It’s about finding a perfect fit for your bike and your lifestyle.
1. Consider Your Bike’s Style and Purpose
Each motorcycle style begs for a different type of tank:
- Choppers: Usually favor elongated, high-mount tanks for that iconic stretched look.
- Bobbers: Often go for compact, minimalist tanks that keep the bike’s profile lean.
- Café Racers: Typically choose narrow, streamlined tanks for speed and retro appeal.
- Cruisers and Touring Bikes: May need larger, more ergonomic tanks for comfort and range.
2. Fitment & Compatibility
Before purchasing, ensure the tank you want is compatible with your motorcycle’s make, model, and year. Check:
- Mounting Points: Will it bolt straight on or require fabrication?
- Tunnel Shape & Size: The underside of the tank must clear your bike’s frame and electrics.
- Capacity: Balance aesthetics with range. Too small a tank might look cool but require frequent fill-ups.
3. Material Choices
Gas tanks are usually made from:
- Steel: Durable, easy to repair, and can be weld-modified or custom-painted.
- Aluminum: Lightweight and naturally resistant to corrosion, but can dent more easily and is costlier.
- Fiberglass: Lightweight and customizable, but tends to be less durable.
- Copper or Brass (Rare): Eye-catching but require more maintenance.
4. Finish Options
You’ll find tanks in several finishes:
- Raw: Ready for you to paint or finish as you choose.
- Painted: Custom painted tanks can feature intricate designs, classic pinstriping, or bold colors right out of the box.
- Powder-Coated: Durable and resistant to chips and scratches.
- Polished/Brushed: Especially popular with aluminum tanks for a vintage or modern touch.
Steps for Installing a Custom Motorcycle Gas Tank
Switching your stock tank for a custom option may seem daunting, but with some patience and the right approach, you can do it confidently. Here’s a basic step-by-step guide:
1. Preparation
- Work Safely: Ensure your bike is turned off and cool.
- Depressurize: Carefully relieve any fuel pressure in the tank.
- Drain Fuel: Use a siphon or drain plug to remove all fuel from the old tank.
- Disconnect Battery: For safety, disconnect the negative terminal to avoid shorts or sparks.
2. Remove the Old Tank
- Remove Seat (if necessary): Most tanks require the seat to be removed first.
- Disconnect Hoses & Wiring: Disconnect the fuel lines, vacuum lines, and any attached electronics (fuel sender, gauge, etc.).
- Unbolt the Tank: Carefully undo the mounting bolts and lift the tank off the frame.
3. Dry Fit the Custom Tank
- Test for Clearance: Position the new tank to check if it fits your frame, clears the engine, and aligns with mounting points.
- Check Tunnel Fit: Ensure the tunnel doesn’t pinch cables, wiring, or frame tubes.
4. Make Any Required Modifications
- Modify Mounts: Some custom tanks require new brackets or adapters. You might need to weld tabs or drill mounting holes.
- Adjust Fuel Lines: Cut or reroute as needed.
5. Final Installation
- Bolt Down the Tank: Use new or existing hardware, ensuring a snug and secure fit.
- Reconnect Lines & Wires: Reattach fuel lines, petcock, and electrical connections.
- Check for Leaks: Add a small amount of fuel, check for leaks at all seams and fittings.
- Replace Seat & Bodywork: Put everything back together.
6. Take a Test Ride
- Short Ride: Take a short test ride to ensure everything works correctly and there are no leaks or issues.
- Retighten Bolts: After your first ride, double-check all hardware.
Benefits of Custom Motorcycle Gas Tanks
Custom motorcycle gas tanks offer more than just aesthetics. Here’s what you can expect:
– Personalized Expression
Your tank can feature pinstriping, bold paintwork, or intricate engraving, reflecting your personal taste and creativity.
– Enhanced Bike Value
A well-chosen and skillfully installed custom tank can boost the value and desirability of your motorcycle.
– Improved Ergonomics
Some custom tanks are reshaped for better knee grip or comfort, making long rides easier.
– Lighter Weight
Aluminum and fiberglass tanks can reduce overall bike weight, improving performance and handling.
Challenges and Considerations
Switching to a custom tank isn’t always straightforward. Be aware of these potential hurdles:
– Fabrication Requirements
Some tanks demand extra fabrication—like welding new mounts or adapting the tunnel—which may require specialized skills.
– Clearance and Compatibility
Fitting a tank that doesn’t match your bike’s frame may cause clearance issues with the handlebars, seat, or electrics.
– Paint and Rust Protection
Raw steel tanks need to be properly painted or sealed inside to prevent rust. Many builders also line the interior with specialty sealants.
– Legal and Safety Issues
Aftermarket tanks must be fuel-tight and safe for street use. Check local regulations for roadworthiness and permitted modifications.
Practical Tips for Custom Gas Tank Success
To maximize your satisfaction and minimize headaches, consider these best practices:
1. Take Precise Measurements
Before buying a tank, carefully measure your bike’s frame and the stock tank’s dimensions. Compare them to the custom tank’s specs.
2. Consult Experts or Forums
Custom bike builders and online communities can offer advice on fitment issues and tank brands known for reliable quality.
3. Get It Professionally Painted
A high-quality paint job not only looks amazing but also adds a layer of protection against rust and weather.
4. Use New Gaskets and Hardware
Never reuse old or worn rubber gaskets, petcocks, or mounting bolts. Fresh parts help ensure a leak-free installation.
5. Seal the Interior
If your tank is raw steel, use a reputable tank sealant to coat the inside and reduce the risk of corrosion or leaks.
6. Plan for Shipping and Customs (if ordering online)
When purchasing from specialty shops or overseas, factor in:
- Shipping Costs: Large items like tanks can be expensive to ship.
- Import Duties: International orders may incur taxes or fees.
- Packaging: Request robust packaging to prevent dents or scratches in transit.
- Return Policy: Make sure the seller has a clear return or exchange policy in case the tank doesn’t fit.
Cost-Saving Tips for Buying and Shipping Custom Tanks
Custom gas tanks can be a significant investment, but a few smart decisions can save money without sacrificing quality.
- Compare Dealers: Check several custom parts shops for the best prices and promotions.
- Buy During Sales: Watch for sales events or off-season deals.
- DIY Installation: If you’re handy with basic tools, installing the tank yourself reduces labor costs.
- Group Shipping: Order multiple items at once to save on combined shipping charges.
- Choose Domestic Suppliers: This often reduces shipping time and import duties.
Conclusion
Upgrading to a custom motorcycle gas tank is one of the most exciting ways to personalize your ride. From unique design choices to improved function and bike value, the right tank can completely transform both the look and the feel of your motorcycle. While the process involves careful planning and may require some hands-on work, the rewards are substantial. By following the steps and advice above, you’ll be rolling down the road on a bike that truly stands out—and reflects your passion for custom craftsmanship.
Frequently Asked Questions (FAQs)
How do I know if a custom gas tank will fit my motorcycle?
Check your bike’s make, model, and year against the tank manufacturer’s compatibility information. Always compare mounting points, tunnel width, and capacity. When in doubt, consult with the seller or an experienced bike builder.
Do I need special tools to install a custom gas tank?
Basic hand tools like wrenches, pliers, and screwdrivers are usually enough for bolt-on tanks. For tanks requiring new mounts or frame modifications, you may need a drill or welding equipment (or help from a professional).
How do I prevent my custom tank from rusting inside?
Use a fuel tank liner or sealant before your first fill-up, especially if the tank is raw steel. Make sure the tank is completely dry before applying the sealant, and follow the product instructions carefully.
Can I reuse my old petcock and hardware?
It’s recommended to use new petcocks, gaskets, and mounting bolts to ensure a tight, leak-free installation. Old hardware may not seal properly or could be worn out.
What should I do if my new tank leaks after installation?
Immediately stop using the tank. Drain any remaining fuel, inspect all fittings and seams, and tighten any loose bolts. If the leak continues, remove the tank and check for cracks or manufacturing defects. Contact the seller for repairs or replacement if necessary.