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DIY Tech Tips

Relocating or Replacing Gas Tank Filler Bung

Relocating or replacing the filler neck in your gas tank not only gives you a custom look, but can help get the most capacity out of your gas tank. Todd wanted to use this Narrow Alien gas tank, which is 2.1 gallons, on a chopper he is building. The tank sits high on the backbone, and he decided to use a Lowbrow rippled gas cap and bung to replace the stock cap and location. When mounted, this allows you to top off the tank without gas sloshing out of the cap when riding.
The first step is to use a bi-metal hole saw to cut the stock filler out. We used a 2-1/2" saw which was a nice fit around the existing bung. Normally hole saws use the pilot bit as a guide, but since this is an open filler bung the snug fit helped keep the hole saw centered while cutting. With a nice clean cut you can save the old gas cap bung for a future fabrication project.
Todd used a die grinder to clean up the inside of the finished hole while I cut a patch to weld in out of a scrap of old fender. A little cutting oil or WD-40 helps with a cleaner, faster cut when using hole saws.
After a bit of time with a grinder and some sand paper we achieved a nice fit. It is ideal to have the patch panel flush or lower, as opposed to raised, as it is much easier to mud it before paint and raise it up to match the existing tank and go for a seamless finish. We used the hole in the patch panel from the pilot bit to hold the panel in place while it was tacked. Be sure you can get the nut out of the tank before welding it in place, or just tack a piece of fill rod to the panel to hold it while you tack it in place
After welding the welds are ground down and then finish sanded with a die grinder with a fine grit sand paper on it to blend it in. We then proceeded to cut the hole for the new filler neck bung.
The new filler neck was held in place and tack welded then checked from all angles to be sure it is right where you want it before finish welding it.
The finished tank is now ready for prep work and paint, and the small amount of time needed to perform this fab work is well worth the effort in the final product!