Method of fabricating a gas tank

• US 6,381,823 B1
• Filed: 01/31/2000
• Issued: 05/07/2002
• Est. Priority Date: 10/29/1999
• Status: Expired due to Fees

• Current Assignee: Kyle P. Krejci
• Original Assignee: Kyle P. Krejci
• Inventors: Krejci, Kyle P.
• Primary Examiner(s): Hughes, S. Thomas
• Assistant Examiner(s): COMPTON, ERIC B
• Application Number:
  US09/494,479
• Time in Patent Office: 827 Days
• Field of Search: 294/63, 294/070.8, 294/16, 220/562, 220/612, 220/678, 220/905, 220/564, 280/830, 280/835
• US Class Current: 29/416
• CPC Class Codes: B23K 11/105 Stitch welding
• CPC Class Codes: B23K 2101/12 Vessels
• CPC Class Codes: B62J 35/00 Fuel tanks specially adapted for motorcycles or engine-assisted cycles; Arrangements thereof fuel tanks forming part of cycle frames B62K11/00; tanks in general B60K ; closure caps for fuel tanks B60K15/0406
• CPC Class Codes: F17C 1/00 Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge pressurised apparatus for purposes other than storage, see the relevant subclasses such as A62C, B05B; associated with vehicles, see the appropriate subclass of classes B60 - B64; pressure vessels in general F16J12/00 ; autoclaves B01J3/04; tank vehicles B60P3/22; railway tank wagons for carrying fluent materials B61D5/00; accumulators for supplying fluid under pressure F15B1/04; liquefied gas stoves F24C3/00
• CPC Class Codes: F17C 13/002 for vessels under pressure F17C13/008 and F17C13/02 - F17C13/12 take precedence
• CPC Class Codes: F17C 2209/221 Welding
• CPC Class Codes: F17C 2223/0123 gaseous, e.g. CNG, GNC
• CPC Class Codes: F17C 2270/0168 by vehicles
• CPC Class Codes: Y10T 29/49796 Coacting pieces
• CPC Class Codes: Y10T 29/49893 Peripheral joining of opposed mirror image parts to form a hollow body

Abstract

A method of forming a gas tank includes forming two halves and welding the halves together. Two types of welds are used, tack welds for holding the complete welds after different steps have been taken to the tack weld elements or parts, and stitch welds to complete the welding of the two halves. Reinforcement is added where necessary. Double tanks, for both gasoline and oil, are also fabricated of essentially the same method steps.

Claims

1. A method of making a gas tank for a motorcycle comprising the steps of:

hydroforming two side halves of the motorcycle gas tank;

tack welding the two side halves together;

cutting out a portion of the tack welded side halves for a bottom tunnel;

forming the bottom tunnel;

welding the formed bottom tunnel to the two side halves;

forming a bottom rear end piece;

welding the formed bottom rear end piece to the two side halves;

welding the tacked side halves to form a tank;

forming mounting brackets;

welding the formed mounting brackets to the welded tank;

drilling holes in the mounting brackets;

drilling crossover holes and petcock holes;

placing tapped mounting bungs, crossover bungs, and petcock bungs in the respective drilled holes;

welding the mounting bungs, crossover bungs, and petcock bungs in their respective holes;

drill a gas cap fitting hole;

positioning a gas cap fitting in the gas cap fitting hole;

welding a gas cap fitting in the gas cap fitting hole;

positioning a seat pocket plate on the gas tank;

welding the seat pocket plate to the gas tank;

cutting off an oil portion to divide the tank into two portions;

welding plates onto the two portions;

drilling an oil cap hole;

welding the two portions together; and

welding an oil cap bung to the oil cap hole.

2. The method of claim 1 which includes the further steps after cutting off the oil portion of:

cutting off a side panel for recessed panel;

drilling holes for return fittings in the recessed panel;

positioning return fittings in the drilled holes;

welding the return fittings in the drilled holes; and

tack welding the recessed panel.

3. The method of claim 2 which includes the further steps of:

drilling fitting holes; and

positioning and welding a breather tube.

4. The method of claim 3 which includes the further steps of:

welding the recessed panel, and

welding fittings in the drilled fitting holes after the two portions have been welded together.

5. A method of making a gas tank for a motorcycle comprising the steps of:

stamping two side halves of the motorcycle gas tank;

tack welding the two side halves together;

cutting out a portion of the tack welded side halves for a bottom tunnel;

forming the bottom tunnel

welding the formed bottom tunnel to the two side halves;

forming a bottom rear end piece;

welding the formed bottom rear end piece to the two side halves;

welding the tacked side halves to form a tank;

forming mounting brackets;

welding the formed mounting brackets to the welded tank;

drilling holes in the mounting brackets;

drilling crossover holes and petcock holes;

placing tapped mounting bungs, crossover bungs, and petcock bungs in the respective drilled holes;

welding the mounting bungs, crossover bungs, and petcock bungs in their respective holes,

drill a gas cap fitting hole;

positioning a gas cap fitting in the gas cap fitting hole;

welding a gas cap fitting in the gas cap fitting hole;

positioning a seat pocket plate on the gas tank;

welding the seat pocket plate to the gas tank;

cutting off an oil portion to divide the tank into two portions;

welding plates onto the two portions;

drilling an oil cap hole;

welding the two portions together; and

welding an oil cap bung to the oil cap hole.