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Author Topic: How to Cut Down a Busa Tank  (Read 18913 times)

Offline Scary-Jerry

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How to Cut Down a Busa Tank
« on: July 23, 2008, 11:01:05 AM »
Let me make some quick comments 1st.
  • An AirTech 'Glass tank is lighter and already done - But it needs to be sealed for Unleaded Glass to not eat the glass.
  • NOTE:  You will have to seal the steel tank as you will be welding it...

This is what I want - This is my Goal...


Tools Needed:
  • Dremel with a Cut-Off Wheel
  • Drill with appropriate Bit
  • MIG Welder
  • Basic mechanical knowledge

Step 1.  Mark the Tank

NOTE: Do NOT Cut all the way around the Front.  This will Keep the Tank centered.


Try to keep the basic Outlines: I wanted to remove the Bulge in the Back that keeps me from getting low.


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...


Now start drilling guide holes to outline where you will cut.
NOTE: Metal must be retained for overlap when welding (dotted Line, etc…).



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…


Here it is removed.  This will allow you to lower the Tank’s Height by pushing the Top down.  So cut it ALL off…


Cut the Tank – I used a Cut-Off Wheel again…
NOTE: DO NOT CUT THE FRONT – Just the corners – This will keep it Centered!



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!



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.



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.


Finish Cutting, Shaping & Trimming.




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.





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…


Clean Your Welds now, as you can see, there was previous damage on the Left Side Top.




Step 5.  Bondo that Tank!

Be liberal with the bondo, as you will remove 80-90% of it.




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…


And now it has come back from the Painter…



Installed:




Any questions???

Good Luck!  :wink:










1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Online sportbikeryder

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Re: How to Cut Down a Busa Tank
« Reply #1 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
Any day on a motorcycle like this that ends just needing parts and labor is a good day.
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Offline Mike-Nightrider

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Re: How to Cut Down a Busa Tank
« Reply #2 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?
« Last Edit: July 23, 2008, 11:39:44 AM by Mike-Nightrider »
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Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #3 on: July 23, 2008, 11:41:15 AM »
That looks really nice Jerry! Great job!

Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #4 on: July 23, 2008, 12:17:03 PM »
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.

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:

1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline jasonsbusa

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Re: How to Cut Down a Busa Tank
« Reply #5 on: July 23, 2008, 12:32:18 PM »
Very nice work Jerry looks great :thumb:

Offline canyon carver

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Re: How to Cut Down a Busa Tank
« Reply #6 on: July 23, 2008, 12:33:07 PM »
Great post.
Faster is Better

Offline quizesilver

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Re: How to Cut Down a Busa Tank
« Reply #7 on: July 23, 2008, 10:07:15 PM »
hardcore! :vl:
talk abt losing weight.
 :thumb:

Offline BADBUSA4U

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Re: How to Cut Down a Busa Tank
« Reply #8 on: July 24, 2008, 12:09:54 AM »
wow

Offline piratediverjefff

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Re: How to Cut Down a Busa Tank
« Reply #9 on: July 25, 2008, 08:48:27 AM »
Nice damn job Jerry,looks great! :thumb:
Build a man a fire and he'll be warm for a day,light a man on fire and he'll be warm for the rest of his life.

Offline dave3.4

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Re: How to Cut Down a Busa Tank
« Reply #10 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

Offline EtrnlSoldier

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Re: How to Cut Down a Busa Tank
« Reply #11 on: July 26, 2008, 09:53:34 AM »
Serious talent!  Bike looks fantastic.   :thumb:
"Straights are for fast bikes.  Turns are for fast riders."

Me.

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #12 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:

Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #13 on: July 26, 2008, 01:15:07 PM »
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...


If you need the seat area, just let me know and I'll take it tomorrow.

1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #14 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. 

Offline jimmygsxr

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Re: How to Cut Down a Busa Tank
« Reply #15 on: July 29, 2008, 08:26:28 PM »
Nice work Jerry, I think you should change careers and become a bike builder.
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Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #16 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




1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline Mike-Nightrider

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Re: How to Cut Down a Busa Tank
« Reply #17 on: July 30, 2008, 08:13:25 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:
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1/8: 5.101s..........1/4: 7.801s
227.7mph Woodbridge/GB 2013

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #18 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:

Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #19 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:
« Last Edit: July 30, 2008, 12:29:03 PM by Scary-Jerry »

1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #20 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:

Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #21 on: July 30, 2008, 03:35:00 PM »
It's another option to consider when Cutting your own...  I thought about it.   :wink:

1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #22 on: July 30, 2008, 03:42:20 PM »
Na, I like how nice the factory looks underneath.

Offline Scary-Jerry

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Re: How to Cut Down a Busa Tank
« Reply #23 on: July 30, 2008, 03:55:06 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:

1999: RCC 'Custom' Stage II Intercooled Turbo System, AMS1000, GSXR Front End & Wheels, Trac Swingarm, Elka Shock, Cut Tank, & a lot of Carbon...

Offline Coryonbusa

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Re: How to Cut Down a Busa Tank
« Reply #24 on: July 30, 2008, 03:58:04 PM »
I know, I thought that. It does look really good. :thumb: