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To solve the fuel problems, most LD riders go to aux fuel setups, often sacrificing the pillion seat, trunk, or a saddlebag. This plus the plumbing, grounding, etc to get theextra fuel to the engine can be annoying. There are some bikes that have custom large tanks- the BMW GS comes to mind. However, I am mostly a believer in keeping it simple. When the dealer dropped Mr Freeze during it's first service, they replaced the tank- and let me keep the old, dented one. What to do, what to do.
I contacted several local welders/ body guys to estimate how much it would cost to enlarge El Dento to near the max allowance (11.5 gal). The range was from 400 to 600 beans, not counting the body work and paint. Youch! Dejected, I was preparing to go to Plan B, aux fuel cell, when George Fetsko came to the rescue. He has a good friend, Rob, who welds all the time- apparently his race car breaks a fair amount. Anyway, George took his Connie over to Rob for an estimate on the cut, and weld job; I figured I can do the crude bodywork myself. Rob's estimate was well under my target of $200, so off El Dento went to Rob.
A few frantic emails were exchanged on sizing, position, etc a short perio of time passed, then the box arrived. I had taken the liberty of ordering Caswell Plating's 2 part epoxy solution for small tanks. I have used this product in the past, and was pleased with the outcome. Easy to use, mix like epoxy and pour it in. Unfortunately, it arrived the day before the inaugural Buckeye 1000.
My end of the project began in earnest the week after the Buckeye, treating, painting, fitting the equipment, etc. I got the entire project completed; total cost was under $200. Usable range is approximately 350 miles to reserve- nice sense of security, since my bladder can't last that long.
Here's a nice photo sequence
 The Beginning Point |
 The Box |
 The Goo |
 Checking the fit |
 Pluggin' holes |
 Goo go inside |
 Paint, paint |
 Putting on the parts |
 Full-Lock turn |
 Pump, pump |
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 But it looks real good with the stickers |
