Method of fabricating a gas tank
First Claim
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1. A method of making a gas tank comprising the steps of:
- providing a quantity of at least sixteen gauge steel;
hydroforming two side halves of the gas tank from the provided at least sixteen gauge steel;
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; and
welding the tacked side halves to form a tank.
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Abstract
A method of making a gas tank includes hydroforming two halves and welding the halves together. Two types of welds are used in welding the two halves together, tack welds for holding the two halves together, and stitch welds to complete the welding of the two halves. Additional steps are taken prior to the finishing stitch welds. Reinforcement is added where necessary. Double tanks, for both gasoline and oil, are also fabricated by essentially the same method steps.
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Citations
19 Claims
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1. A method of making a gas tank comprising the steps of:
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providing a quantity of at least sixteen gauge steel;
hydroforming two side halves of the gas tank from the provided at least sixteen gauge steel;
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; and
welding the tacked side halves to form a tank. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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 the gas cap fitting in the gas cap fitting hole;
positioning a seat pocket plate on the gas tank; and
welding the seat pocket plate to the gas tank.
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3. The method of claim 2 which further includes the step of cleaning out the interior of the welded tank prior to the step of welding the gas cap fitting.
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4. The method of claim 2 which further includes the step of pressure testing the tank after welding the gas cap fitting into the gas cap fitting hole.
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5. The method of claim 1 in which the step of welding the tacked side halves further includes the step of stitch welding the tacked side halves.
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6. The method of claim 1 in which the step of hydroforming two side halves includes the further step of trimming excess material from the hydroformed side halves.
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7. The method of claim 1 which further includes the step of welding a sheet metal reinforcing strip to the inside of the two halves after the side halves have been cut to form a bottom tunnel.
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8. The method of claim 1 in which the welding steps include stitch welding.
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9. The method of claim 1 which includes the further steps of:
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cutting off an oil portion to divide the tank into two portions;
welding plates to the two portions;
drilling an oil cap hole;
welding the two portions together; and
welding an oil cap bung to the oil cap hole.
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10. The method of claim 9 which includes the further steps, after the step of cutting off the oil portion, of:
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cutting off a side panel for a 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.
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11. The method of claim 10 which includes the further steps of:
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drilling fitting holes; and
positioning and welding a breather tube.
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12. The method of claim 11 which includes the further steps of:
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welding the recessed panel; and
welding fittings in the drilled fitting holes after the two portions have been welded together.
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13. A method for making a motorcycle gas tank comprising the steps of:
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providing a quantity of at least sixteen gauge steel;
hydroforming two side halves for the tank from the provided at least sixteen gauge steel;
tack welding the two side halves together;
cutting out a portion of the welded side halves for a bottom tunnel;
forming a bottom tunnel;
welding the formed bottom tunnel to the two side halves; and
welding the tacked side halves to form a tank. - View Dependent Claims (14, 15, 16, 17, 18, 19)
forming a bottom rear end piece, and welding the formed rear end piece to the two side halves. -
17. The method of claim 13 in which the step of hydroforming two side halves includes the further step of trimming excess material from the hydroformed side halves.
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18. The method of claim 13 which includes the further steps of:
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forming mounting brackets;
welding the formed mounting brackets to the welded tank;
drilling holes in the mounting brackets;
drilling crossover holes and petcock holes in the welded tank;
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;
drilling a gas cap fitting hole;
positioning a gas cap fitting in the gas cap fitting hole; and
welding the gas cap fitting in the gas cap fitting hole.
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19. The method of claim 18 which includes the further steps of forming a rear end piece and welding the formed rear end piece to the two side halves.
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Specification