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TECHNICAL => MODS => Topic started by: Scary-Jerry on July 23, 2008, 11:01:05 AM

Title: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 23, 2008, 11:01:05 AM
Let me make some quick comments 1st.

This is what I want - This is my Goal...
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/01.jpg)

Tools Needed:

Step 1.  Mark the Tank

NOTE: Do NOT Cut all the way around the Front.  This will Keep the Tank centered.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank001.jpg)

Try to keep the basic Outlines: I wanted to remove the Bulge in the Back that keeps me from getting low.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank004.jpg)

I also wanted the small side Bulges removed – If you do, you can’t run a stock seat! Seat Pan required!!!
NOTE:  I will explain how you can still use the Stock Seat later...
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/3Removebulge.jpg)

Now start drilling guide holes to outline where you will cut.
NOTE: Metal must be retained for overlap when welding (dotted Line, etc…).
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank005.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/6.jpg)

Step 2.  Cut that Tank

Next – Remove Filler Cap Neck (Round Metal Sleeve).
NOTE:  I used a Dremel with a Cut-Off Wheel to fit and it cut it very nice. 
Don’t worry if it falls in, you will be able to get it out later…
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank013.jpg)

Here it is removed.  This will allow you to lower the Tank’s Height by pushing the Top down.  So cut it ALL off…
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/8.jpg)

Cut the Tank – I used a Cut-Off Wheel again…
NOTE: DO NOT CUT THE FRONT – Just the corners – This will keep it Centered!
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/DontCutFront.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank010.jpg)

Note: In the above Pic, I discovered it would be easier to just remove the Side Panel and weld it back in.

Step 3.  Shape that Tank

Just Push down in the Back.  Look at the Gap created, this is where you will Sit now.  So make it Flat!
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank011.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank012.jpg)

As for the Vent Tubes in the Tank – DO NOT CUT THEM!  They will bend and be fine…
NOTE:  I was able to retain the Float Gauge too.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank025.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank024.jpg)

Note the above Pic of the Vent Tubes & Petcock Bowl: 2000 Tank.

Continue to shape the Tank by bending the Back to form a Seat Area.
FYI – Angle it downward more than I did as when it is mounted, it goes upward.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank016.jpg)

Finish Cutting, Shaping & Trimming.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank015.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank019.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutDownTank017.jpg)

NOTE:  Make it Narrower in the Back than I did, and you can use a stock seat with it…
…and draw many Centerlines.

Step 4.  Welding the Tank
NOTE:  Go slow as to not warp the Tank.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/StitchWeld.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/WeldTank.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/Welded.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/ProfileRS.jpg)

FYI – Don’t worry about the welds nor making it Air Tight.  You can always grind off the welds and you will be Sealing it anyways to prevent Rust.
NOTE:  The MIG Welder I borrowed was Crap at a Public Craft Shop – I really can weld better…

Check your Symmetry often – Left side is lower…
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/Semetry.jpg)

Clean Your Welds now, as you can see, there was previous damage on the Left Side Top.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CleanWeldsLS.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CleanWeldsFront.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CleanWeldsRS.jpg)

Step 5.  Bondo that Tank!

Be liberal with the bondo, as you will remove 80-90% of it.
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/28.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/27.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/29.jpg)

And then Prime it so you can block it out prier to giving it to your Painter.
You’re a cheap basterd, that is why you went to all this Trouble…
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/Busa001.jpg)

And now it has come back from the Painter…
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CuttankLS.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutTank.jpg)

Installed:
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CompletedAgain004.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CompletedAgain012.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CompletedAgain008.jpg)

Any questions???

Good Luck!  :wink:









Title: Re: How to Cut Down a Busa Tank
Post by: sportbikeryder on July 23, 2008, 11:19:22 AM
Looks Great!
What did you end up sealing it with? That white stuff for inside gas tanks?
John
Title: Re: How to Cut Down a Busa Tank
Post by: Mike-Nightrider on July 23, 2008, 11:38:03 AM
Very good job, Jerry. 

:thumb:  :thumb:  :thumb:

I have seen the tank in reality, guys.
Looks fantastic.

How much fuel can you fill in after the modification?
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 23, 2008, 11:41:15 AM
That looks really nice Jerry! Great job!
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 23, 2008, 12:17:03 PM
Quote from: sportbikeryder on July 23, 2008, 11:19:22 AM
Looks Great!
What did you end up sealing it with? That white stuff for inside gas tanks?
John


I used an Acrylic Epoxy - Clear from a company in the Netherlands (Holland).
DO NOT USE KREEM to SEAL TANKS = SUCKS!!!
There are many good ones on the Internet, just google it and you will some nice stuff.

Quote from: Mike-Nightrider on July 23, 2008, 11:38:03 AM
Very good job, Jerry. 

:thumb:  :thumb:  :thumb:

I have seen the tank in reality, guys.
Looks fantastic.

How much fuel can you fill in after the modification?

I hold 12 liters, about 3 gallons now.  :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: jasonsbusa on July 23, 2008, 12:32:18 PM
Very nice work Jerry looks great :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: canyon carver on July 23, 2008, 12:33:07 PM
Great post.
Title: Re: How to Cut Down a Busa Tank
Post by: quizesilver on July 23, 2008, 10:07:15 PM
hardcore! :vl:
talk abt losing weight.
 :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: BADBUSA4U on July 24, 2008, 12:09:54 AM
wow
Title: Re: How to Cut Down a Busa Tank
Post by: piratediverjefff on July 25, 2008, 08:48:27 AM
Nice damn job Jerry,looks great! :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: dave3.4 on July 25, 2008, 06:53:09 PM
that  looks nice! If I knew how to weld I think I would try to make one myself after seeing how good yours came out..Great jb
Title: Re: How to Cut Down a Busa Tank
Post by: EtrnlSoldier on July 26, 2008, 09:53:34 AM
Serious talent!  Bike looks fantastic.   :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 26, 2008, 11:39:30 AM
Hey Jerry, can post a pic from straight on behind the bike looking over the hump at the tank?
I want to see the lines of the seat to the tank and the width of the seat to the tank area.
:thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 26, 2008, 01:15:07 PM
Quote from: Coryonbusa on July 26, 2008, 11:39:30 AM
Hey Jerry, can post a pic from straight on behind the bike looking over the hump at the tank?
I want to see the lines of the seat to the tank and the width of the seat to the tank area.
:thumb:

Here is one I have...
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/RollinAgain007-1.jpg)

If you need the seat area, just let me know and I'll take it tomorrow.
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 26, 2008, 01:40:13 PM
Yeah that angle, but up and over the hump. Showing the seat and the tank. :thumb:
Thank you. 
Title: Re: How to Cut Down a Busa Tank
Post by: jimmygsxr on July 29, 2008, 08:26:28 PM
Nice work Jerry, I think you should change careers and become a bike builder.
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 30, 2008, 06:20:59 AM
Thanks Guys for the Compliments - Maybe when I get back to the States, not a lot of demand for it over here in Germany.

PICs from all angles... don't mind the missing motor.  It's in pieces waiting for Rod Bolts, I should be all done and fired up this weekend...  :D
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutTankSeat003.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutTankSeat002.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutTankSeat004.jpg)
(http://img.photobucket.com/albums/v156/Scary-Jerry/Hayabusa/LE%20TurboBusa/CutTankSeat006.jpg)
Title: Re: How to Cut Down a Busa Tank
Post by: Mike-Nightrider on July 30, 2008, 08:13:25 AM
Quote from: Scary-Jerry on July 30, 2008, 06:20:59 AM
Thanks Guys for the Compliments - Maybe when I get back to the States, not a lot of demand for it over here in Germany.

Yes, you are right.
Most German ride the busa as a touring motorcycle.  :puke:
But I am the first guy  :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 30, 2008, 11:24:14 AM
Thnaks for the extra pics Jerry. :thumb:
I see what you're saying about cutting the tank a little flatter with the line of the seat. Might leave a little more "ball" room. :D

I might steal your idea, if you don't mind. :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 30, 2008, 11:47:31 AM
That's why I posted it... nobody else would.  :wink:

It's not that difficult now that you have a visual... don't forget to SEAL it!

Now you have to weigh the cost of your time & materials and look at the AirTech Glass tank... it needs sealing too.   :?







FYI - Gatlin Racing will do one for $1,095 + your Tank + SH.  :bah:
(http://www.gatlinracing.com/products/suzuki/gsx1300r/slammed_tank1.jpg)(http://www.gatlinracing.com/products/suzuki/gsx1300r/slammed_tank4.jpg)
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 30, 2008, 03:25:15 PM
:shock: And it's not any flatter than yours on front of the seat! That's too expensive.

Looks like it'll give you more room under the hood, though. :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 30, 2008, 03:35:00 PM
It's another option to consider when Cutting your own...  I thought about it.   :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 30, 2008, 03:42:20 PM
Na, I like how nice the factory looks underneath.
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on July 30, 2008, 03:55:06 PM
Quote from: Coryonbusa on July 30, 2008, 03:42:20 PM
Na, I like how nice the factory looks underneath.

And it makes it that much more Stealthy... nobody notices until you say something.  8)

Mine was on there and Pics posted since March with it cut down...  :lol:
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on July 30, 2008, 03:58:04 PM
I know, I thought that. It does look really good. :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on November 17, 2009, 08:57:47 AM
People asking again - so, to the top...  :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: genarr3 on November 17, 2009, 09:12:37 PM
I see you've cut down an external fuel pump tank, will this work as posted with an internal pump? Good job by the way, looks great. I think I'm going to do one over the winter.
Title: Re: How to Cut Down a Busa Tank
Post by: TrickTom1 on November 17, 2009, 09:20:13 PM
 :thumb: Jerry
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on November 18, 2009, 07:40:44 AM
Quote from: genarr3 on November 17, 2009, 09:12:37 PM
I see you've cut down an external fuel pump tank, will this work as posted with an internal pump? Good job by the way, looks great. I think I'm going to do one over the winter.

Quite sure it will as the Fuel Guage fits too and it attaches internally the same way.   :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: EXTREMEFUN1300 on November 20, 2009, 07:15:25 AM
Damn Jerry, that's some serious work & talent there brotha.  Incredible job well done!   :thumb:
I see an new TV program coming next season...Scary Jerry's Choppers!   :)

Not that I could do something like that...but you forgot one MAJOR step in the beginning of the process.......






DRAIN THE GAS!!!!!!!                     :hys:
Title: Re: How to Cut Down a Busa Tank
Post by: smithabusa on November 20, 2009, 07:33:38 AM
(http://archivos.metatube.com/uploads/videos/thumbs/img_webmaster_1219439117.jpg)
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on November 20, 2009, 01:01:36 PM
 :hys:
Title: Re: How to Cut Down a Busa Tank
Post by: Twistedspeed on February 08, 2010, 11:41:30 AM
So anyone esle done it? Curious about getting one done if another member has. I have no welding skills at all.
Title: Re: How to Cut Down a Busa Tank
Post by: Cookie on February 08, 2010, 02:40:41 PM
Man, Jerry,, you are amazing. Is there anything you don't do? Are you married?  :bah: :lol: :hys:

How much did you actually reduce down in volume? Liters please!
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on February 08, 2010, 03:46:44 PM
Quote from: Cookie on February 08, 2010, 02:40:41 PM
Man, Jerry,, you are amazing. Is there anything you don't do? Are you married?  :bah: :lol: :hys:

How much did you actually reduce down in volume? Liters please!

Sorry - have to convert = Holds about 3.5 gallons now.

I do it out of neccessity as I am a Cheap bastard...  :hys:
Title: Re: How to Cut Down a Busa Tank
Post by: Coryonbusa on February 08, 2010, 05:18:11 PM
Glad this is back on top. I just scored a tank from TDCFrank. :thumb:
Gonna atempt a prostreet style tank. :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: Cookie on February 08, 2010, 10:33:50 PM
Quote from: Scary-Jerry on February 08, 2010, 03:46:44 PM
Quote from: Cookie on February 08, 2010, 02:40:41 PM
Man, Jerry,, you are amazing. Is there anything you don't do? Are you married?  :bah: :lol: :hys:

How much did you actually reduce down in volume? Liters please!

Sorry - have to convert = Holds about 3.5 gallons now.

I do it out of neccessity as I am a Cheap bastard...  :hys:

 :thumb: Damned talented cheap bastard! I love looking over your bike,, any day of the week. There is always great hings to watch and be guided by! Again!  :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: nickelcityracing on February 11, 2010, 08:26:12 AM
nice tank, I have cut and slammed 2 tanks for our LSR bike, they turned out very nice
Title: Re: How to Cut Down a Busa Tank
Post by: Twistedspeed on February 11, 2010, 12:21:17 PM
Quote from: nickelcityracing on February 11, 2010, 08:26:12 AM
nice tank, I have cut and slammed 2 tanks for our LSR bike, they turned out very nice

Do you offer this as a service??
Title: Re: How to Cut Down a Busa Tank
Post by: nickelcityracing on February 11, 2010, 03:01:21 PM
Quote from: Twistedspeed on February 11, 2010, 12:21:17 PM
Quote from: nickelcityracing on February 11, 2010, 08:26:12 AM
nice tank, I have cut and slammed 2 tanks for our LSR bike, they turned out very nice

Do you offer this as a service??
I did sell one of the tanks I made, Charlie on here bought it, I could make you one depending on what exactly you want..? send me an email and i will send you pics of what i did and we will see....  thanks jody     nickelcityracing@persona.ca
Title: Re: How to Cut Down a Busa Tank
Post by: Twistedspeed on February 11, 2010, 07:09:36 PM
Email sent
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on August 24, 2010, 03:02:54 PM
Back to the Top once again - Maybe a Sticky is needed...  :wink:
Title: Re: How to Cut Down a Busa Tank
Post by: Mike-Nightrider on August 24, 2010, 03:04:00 PM
Quote from: Scary-Jerry on August 24, 2010, 03:02:54 PM
Back to the Top once again - Maybe a Sticky is needed...  :wink:
:thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: piratediverjefff on August 24, 2010, 03:43:18 PM
Quote from: Coryonbusa on February 08, 2010, 05:18:11 PM
Glad this is back on top. I just scored a tank from TDCFrank. :thumb:
Gonna atempt a prostreet style tank. :thumb:

Alright Cory,it's been 6 months...where's the damn tank?! :lol:
Title: Re: How to Cut Down a Busa Tank
Post by: Grumpy 69 on August 27, 2010, 07:14:04 AM
 well done, looks great  :thumb: :thumb:
Title: Re: How to Cut Down a Busa Tank
Post by: cora on October 07, 2012, 08:48:32 AM
i know its a old  topic but, how did u manage to seal the tank good???
with what did u clean the tank inside before cutting it??!
Title: Re: How to Cut Down a Busa Tank
Post by: piratediverjefff on October 07, 2012, 08:59:46 AM
Quote from: cora on October 07, 2012, 08:48:32 AM
i know its a old  topic but, how did u manage to seal the tank good???
with what did u clean the tank inside before cutting it??!

...i think he went out back to take a shit and the hogs ate him. :lol:

(haven't seen Cory on here in a long time bro...Cory,are you out there buddy?!)
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on October 10, 2012, 07:50:27 PM
Quote from: cora on October 07, 2012, 08:48:32 AM
i know its a old  topic but, how did u manage to seal the tank good???
with what did u clean the tank inside before cutting it??!

Clean it with Muriadic Acid (Swimming Pool Acid) and seal with an Epoxy Resin (Google Tank Seal Kit).
Title: Re: How to Cut Down a Busa Tank
Post by: cora on April 03, 2013, 09:55:00 AM
Scarry jerry what type of welding wire did u use??
Because i did cut my tank and took it to welding shops and they told me they cant weld it with mig.they have to do it with another process.
Title: Re: How to Cut Down a Busa Tank
Post by: Scary-Jerry on April 04, 2013, 06:18:49 AM
I MIG Welded it with CO2/Argon Gas = Standard everyday stuff...  I'm sure you could do it with Flux Core wire too.
They must think the metal is too thin a Guage or they are B.S.'ing you...