bsa tank but not single

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madmac
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bsa tank but not single

Postby madmac » Sat Sep 27, 2014 3:56 pm

Hi All BSA but not single related.
A new Quest has appeared, on the way to the west yorkshire camp earlier in the year my spitfire petrol tank decided to give up the battle against ethanol fuels even after using sealer it gave up, the seams were splitting in front of my eyes and a constant drip of petrol or whatever it is dripped on the engine and more worrying my leg
many thanks to all who helped stem the flow but in the end i gave up and borrowed a thunderbolt tank to get me home
well this leads me to my new quest
1. seal again ? don't think this is ever going to work satisfactory
2.buy indian tank ? possible Just under £300 with a few concerns of fit .
3. make one?? well have some steel sheet, have dolly and hammer, have welder ,have blind faith <127 and read a book
P1000779.JPG

Made a ply template of base
Next a bit of tank, first attempt was going to be two half sides but for a first attempt at steel forming this was a bit difficult so decided on three sections top and two sides
P1000770.JPG
bottom and top

Had to make a tucking fork to shrink the metal as you can only stretch it so much then it gets thin
the idea is to make a tuck in the steel then work the metal in on itself with a hammer
P1000776.JPG
tucking fork

picked up a cast iron wheel and a pillar block bearing which has a radius on it and made a frame
Then its all about wheeling back and forth trying to wheel out the tuck marks
P1000778.JPG
wheel

P1000781.JPG
top and two sides

well thats all for the moment lots to do

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Re: bsa tank but not single

Postby Canberra » Sun Sep 28, 2014 2:41 pm

Maybe it would look good on a B50? Keep on going please - you may have a market somewhere.
John

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Re: bsa tank but not single

Postby roadplough » Wed Oct 01, 2014 4:43 am

Great stuff madmac, especially making the tools yourself.
I guess you must have to stand on the panel to use the tucking fork!

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Re: bsa tank but not single

Postby beat » Wed Oct 08, 2014 9:43 pm

looks good madmac.
I was using Alu 1.5 MM , it weights less in the hand and forms easier plus saves the painting ;-)
and still enjoying it....
beat :grin:

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Re: bsa tank but not single

Postby madmac » Tue Nov 11, 2014 12:09 am

Hi all
had a couple of hours to tinker with tank tonight,though I would have a go at the star badges
The plan was to make a positive and a negative of the star out of steel and roll into the tank
P1000808.JPG
pos and neg

Then place positive on the front of tank and the negative exactly behind on the inside ,Then under the roller and roll
P1000846.JPG
star result

well thats all at the moment but well chuffed <215
P1000845.JPG

The tank filler neck impression is next but this has me stumped at the moment <201

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Re: bsa tank but not single

Postby HPbyStan » Tue Nov 11, 2014 2:39 am

You are one clever dude

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Re: bsa tank but not single

Postby roadplough » Tue Nov 11, 2014 3:24 am

Very cool!
madmac wrote:filler neck impression is next but this has me stumped at the moment

good to have a challenge :roll:

A cheap hydraulic [pipe bending] press and a few taper bearing rings?

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Re: bsa tank but not single

Postby beat » Tue Nov 11, 2014 10:24 pm

great work !!!!
beat :thumb

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Re: bsa tank but not single

Postby madmac » Tue Nov 11, 2014 10:59 pm

Thanks for the encouragement <021 as I have been told at work it's not a challenge ,It's an opportunity to excel
Mac

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Re: bsa tank but not single

Postby minetymenace » Wed Nov 12, 2014 12:25 am

Excel away
:shock:
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Re: bsa tank but not single

Postby madmac » Mon Nov 17, 2014 12:49 am

Hi All
well I should be working on the B25,but have to do something with this tank I've Been putting of the welding bit for too long
P1000868.JPG

I left my options open with the three sections, by bringing the center section further over than necessary this gave me the option to cut top or side to fit
P1000871.JPG

so I cut most of the center section away to fit
P1000869.JPG

Now the fun begins welding up without burning holes
P1000867.JPG

Decided not to form the indent for the filler as it works out to close to the welded section
well thats all I got done today hope Its of interest <201
Mac

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Re: bsa tank but not single

Postby skippy » Mon Nov 17, 2014 6:18 am

It is very interesting thanks.
Doug
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Re: bsa tank but not single

Postby madmac » Mon Dec 15, 2014 1:09 am

Hi all
been in the garage again managed to get the filler done,started with knocking the indent in
P1000877.JPG
hole for the filler neck

bit more bashing around
P1000881.JPG
This is still not deep enough, thought it would split or completely distort the tank

managed to weld the filler neck in place
P1000885.JPG
Took some bashing but managed to weld in place, square as well

Now the job gets interesting trying to fit the two halfs, I made the bottom first so the welding leaves a lot to be desired
The fit wasn't to bad but at one point I was 1/2" short so had to cut out and extend
P1000890.JPG
Short of top woops

Took a little fiddling but looks ok , made some bushes for the petrol taps and welded in made the same as originals 3/8"bsp could have gone straight for 1/4" but those bsa men did it for a reason who knows?
P1000893.JPG
petrol tap bushes and trial fit of bottom

last job of the day trying to close the ends , I would just say what a pain <218 not a straight edge to work to so more bashing later this week
P1000894.JPG
This is going to test my patience

Bye for now MM

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Re: bsa tank but not single

Postby beat » Mon Dec 15, 2014 8:51 pm

:thumb :thumb :thumb :thumb

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Re: bsa tank but not single

Postby madmac » Tue Dec 30, 2014 12:21 pm

Hi all managed to get some garage time in
between another cold and working calls over christmas
The end fillers did prove to be a pain so many changes of direction and running out of cereal boxes to make templates,so many unmarked bags of cereals in the cupboards
P1000899.JPG
cereal box template

The center fixing tube next, drilling a hole into the top of the tank did not seem right some how, we'll measure twice and cut once thats the way to do it,worked out ok
P1000910.JPG
hole in tank

also decided to stiffen the tank with some plates seen so many tanks split and this is going to be a heavy tank when full of fuel
P1000908.JPG
stiffener

Now just need the two bolts at the front for the tank support and close it up,
P1000911.JPG
bottom and top
Time to tidy garage as cant find Bracket to mark bolts <201MM

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Re: bsa tank but not single

Postby packw » Tue Dec 30, 2014 10:49 pm

Hi madmac,
Wonderful, inspirational stuff. You can probably now understand why the Indian-made tanks appear to cost so much.
I see you are from Tyne & Wear. I live in sunny South Shields and I'd love to see your tank in the flesh as it were.
Cheers
Bill

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Re: bsa tank but not single

Postby madmac » Wed Dec 31, 2014 10:27 am

Hi Bill sent you pm
Ian

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Mark Cook
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Re: bsa tank but not single

Postby Mark Cook » Wed Dec 31, 2014 12:55 pm

I am so jealous of the things some of you all get up too, this has to be one of the most inspiring for me. I know time and funds make it hard to play, but I'm very impressed all the same.
I'm going to ask my Boss if I'm allowed to retire next year in the hope I'll have more personal time.
I've been reminded that I still have 3 years work to catch up on since fracturing my spine. Retirement seems like a good way of getting out of it ;-)
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Re: bsa tank but not single

Postby minetymenace » Wed Dec 31, 2014 6:30 pm

No rest for the wicked Mark <096

I was just thinking "I could do that", the only problem is, I couldn't.
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Re: bsa tank but not single

Postby madmac » Fri Jan 02, 2015 8:11 pm

Well funny you should say that Mark I've handed my notice in at work and going to retire in March for a bit more me time, I've heard It's recommended
Anyway got the tank finished
P1000912.JPG
tank on bike

Had a sweat on when welding the bottom in, I really did not have a clue how I was going to weld it
The bottom of the tank has a bead all the way round so thought about welding inside to this,but this melts the outer shell or just weld straight down onto both skins
P1000915.JPG
top of photo is the top and bottom skin joint

Bit of grinding squares this up but next time I would make the bottom flange overhang top skin
P1000916.JPG
bottom of tank

Well I think thats it, well maybe a pressure test and then paint, will post a photo when done thanks for the encouragement MM

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Re: bsa tank but not single

Postby Mark Cook » Fri Jan 02, 2015 9:49 pm

Don't pressure test it, does not take much pressure to bugger one :oops:
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Re: bsa tank but not single

Postby madmac » Sun Mar 15, 2015 11:37 am

Hi all
I was along admiring packw tribsa yesterday, a good job Bill I have to say , and he reminded me I need to update this thread so just a couple of photos of the bike and tank with fuel in the tank :ban


P1000996.JPG

It came out better than I hoped for the star impression is not quite right but Im happy
Now lots of cleaning as the bike is next to where I cut grind and spray, and I found out the hard way on my first ride to sweep up all the metal cuttings, who got a puncture :???:
P1000994.JPG
1967 spitfire
Attachments
P1000995.JPG

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Re: bsa tank but not single

Postby Richard Hunt » Sun Mar 15, 2015 2:55 pm

Very nice madmac :thumb

Rich

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Re: bsa tank but not single

Postby HPbyStan » Sun Mar 15, 2015 3:56 pm

That turned out really well !

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Re: bsa tank but not single

Postby packw » Sun Mar 15, 2015 9:02 pm

I would certainly second that.
madmac has done a great job. You might expect that he would have a palatial garage to accomplish such work, but believe me it is very tight.
The photos really do the tank justice. It looks great on the bike.
Cheers
Bill

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Re: bsa tank but not single

Postby beat » Sun Mar 15, 2015 9:07 pm

looks better than new BSA stuff :!: :!:
:ok :thumb <200

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Re: bsa tank but not single

Postby malcward » Tue Sep 29, 2015 11:40 pm

Bit late , but just seen this thread ,
Fantastic work :thumb , would you consider selling parts to make a tank up ,i.e. in kit form or would sell patterns to make one up from ?

Cheers
Malc


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