Many thanks for all the info, there's a few good pointers, as for the welding I guess it all depends on how confident you are and if it's someone else's property that's going to cost you I know there's guys out there who could weld cooking foil but that sort of class won't come cheap   once again thanks

Just a quick update - I decided to let a friend loose on it and here are the results the guy who is going to paint it says he'll fill it and gently slope the filler from near the edge of the tank to top of the lip of the hole so hopefully you won't notice that the hole was there. I think hes done a good job of the welding - no holes and fairly neat. A bit of grinding and bobs your uncle, cheers all

looks a good job to me.

ahh minis - plenty of welding practise there  
I used to own a mini van in my yoof - new owner is probably trying to weld it back together right now.
Miss it.

justin_o_guy2 wrote on 08/19/15 at 05:46:24:


The bead looks big, as the lip where the speedometer hole meets the tank top is still in place.  The welded in sheet appears to be sitting on the inside of the bead.

chzeckmate wrote on 08/19/15 at 15:34:14:

Judging by pictures the mounts on the GV250 tank seems to be a bit more forward than our tank. But if it could be made to fit that'd be pretty sweet -  14l capacity and fuel gauge built in.

Dave, I'm still droolin over that tank. Can't wait to see the next one might buy it if for sale. Hope mine turns out that smooth. A tank Suzuki should have built. I like that gas cap you got on there Steddy but I'd be leary off a little grinding and Bob's your uncle. That plate is welded below the lip(two seperate pieces of thin metal) and grinding it down could seperate it. If you haven't already pressure tested it  just to check the welds and let your buddy know how well he did. I would do it after grinding the welds down to prepare for body filler and paint. Unless your speaking of sanding the body filler down to smooth it for paint. What I understood, he's going to put body filler from all the edges of your tank, raising your profile up say a 1/4" to match the lip. Essentially keeping the same shape but making it wider(thicker) a 1/4" all over till it evens out with the lip? If so,  it sounds cool just wanted to let you know to be careful about smoothing out those welds. My plate sits on top the lip and I'm nervous. Dave, how was your plate sitting? I've seen the before and after paint pics but not any before the body filler. Did you smooth out your welds or did they look like pennies layered( smooth already)? Idk if this is a difference between tig and mig welding but mines has the large weld bumps too.

Also if i can upload the pics. A 1987? 1989? Yamaha virago tank 1 1/2" cut out the middle and ??? how much cut of the end. A friends project for a cb550 project before he found another tank. He might use it on a savage build, been trying to talk him into to getting one.  Has a deep channel and that cable looks like a fuel gauge. [img]http://i42.photobucket.com/albums/e303/askim4201/Mobile%20Uploads/20150801_173541_zpsaxmhktxb.jpg" alt="" title="" border="0" />[/img]

[img]http://i42.photobucket.com/albums/e303/askim4201/Mobile%20Uploads/20150801_173555_zps7ns6ish2.jpg" alt="" title="" border="0" />[/img]

[img]http://i42.photobucket.com/albums/e303/askim4201/Mobile%20Uploads/20150801_173606_zps94bzqw8t.jpg" alt="" title="" border="0" />[/img]

[img]http://i42.photobucket.com/albums/e303/askim4201/Mobile%20Uploads/20150801_173623_zpsab2dxnar.jpg" alt="" title="" border="0" />[/img]

[img]http://i42.photobucket.com/albums/e303/askim4201/Mobile%20Uploads/20150801_173742_zps07duguet.jpg" alt="" title="" border="0" />[/img]

Would it be possible to put the GV250 sending unit and fuel gauge into the stock savage tank? Looks like 3 holes but would need to be mounted into the right spot to give an accurate reading.