Never to old to learn

[Dave Z.]

Hello all, I been hunting info on sheet metal working and came across this site. looks like the right place to ask questions and maybe share info. I don't know a lot about metal forming by hand and that's why Im here...Im looking to learn. I have over 30 years under my belt doing machine work and fabrication/repair work. I make a lot of my own motorcycle parts and want to try making sheet metal parts too...thanks for any help you can give!

[Jere]

Hello Dave and welcome to the forum.

You will find lots of help here, just ask. And we like lots of pictures.

Jere

[Peter Tommasini]

Hi Dave welcome to the forum
Peter

[Dave Z.]

Wow...Im bouncing around on here and the info and talent is incredible. Looking gives me ideas...the mind's wheels start turning and then look out....so much to read here and put to practice Ill never want to sleep! And thanks for the welcome in!

[Jere]

Dave do you have a project you are working on now? Post some photos if you are.

Jere

[Dave Z.]

Yes...I am working on Harley fuel tanks. My bike has fat bob tanks which are actually two separate tanks. The tanks I have are stretched tanks which are longer than stock tanks. Well they are to wide for my liking so I cut the "flat" side out of the tank and cut about 3 inches out of the width of the tanks...to narrow them. My first attempt was to reuse the flat side of the tank and re weld it into the newly narrowed tank shell. Well...little did I know that MIG welding and without purging was sure failure. I pressure tested the tanks and they leaked like crazy. THEN I asked experienced welders what I did wrong and learned my lesson. So....now I once again cut out the flat side of the tank but this time it wasn't reusable. So I had to form a new side. I made a plywood form to fit the shape I needed and formed my new side over it. I ran into problems with making a curved flange, as the metal wanted to ripple kinda like the curved edge of a tin dust pan. I solved that by making cuts to allow it to overlap, then I trimmed the overlap and welded the cut back to solid. What led me here is the burning question...is this how its done. I try to do anything I do "right". I started looking up metal shaping info and found this site. Even before this project I had great interest in metal forming. Actually hand formed parts. Jesse James and his bikes and his metal skills always fascinated me. Id love to know half what he does. Ill try to get some pics up of what Im describing with my project. Im going to try TIG welding my new side onto the shell with silicon bronze rod this time. I have a welder friend that said that's the best way to go here. Anyway...Im really looking forward to doing more metal work and learning also.

[Dave Z.]

My bike now...It will look the same from the side...just more narrow from the top...

[Dave Z.]

Ok...I found some pics from my first attempt and how I want this to look. The pic of the bike with orange tanks is the current tank setup. The bare metal ones are the new ones...or should I say victims. Ill post up some pics of what I got going now, as soon as can. Im sure to you guys this would be a cake job but for me its a bit of a challenge especially making it fit the shell nice and tight. Im trying to get a nice over lap for a weld joint and its not as easy as I thought....LOL

[Jere]

Dave try tuck shrinking rather than cutting wedges. The material will flow much nicer and requires less metal finishing.

Jere

[Dave Z.]

I watched videos on tucking but still not exactly sure how to do it. I get the principle behind it but to apply it to a hard bend such as mine it seems impossible. I tried to upload pics of what I made but it wont let me. It errors saying a security token is missing...whatever that is...