BOBD wrote on 10/13/12 at 12:09:15:Has anyone made a 3 gal. plus reserve gas tank for the S40? I think the best way would be to modify the tank by cutting it in half and welding a piece down the middle. I don't have the equipment to do that. Has anybody on here tried it?
I got a spare tank (old, dented, $1 off ebay) and go into cutting in half horizonally. Taped cardboard to see how it would look -- nice. I figured making it about 2 inches taller. You probably even notice it.
I was going to cut the top and bottom, move the gauges to the handlebar. As far as I could measure, I would end up with 4.5 gallons, get or take a half.
Then I started brazing the patch..... I need more practice..... It is still in half, rusting......