After selling my old Sportster tank to Harry, I needed a fueltank for my
own bike. I had a brandnew Sportster tank with aircraft style cap and
rubbermounts and I had a very old and damaged King Sportster left.

 

Because everybody has an aircraft-style cap nowadays, and because
I think the old tank has better lines, I decided to modify the old tank
with a new fuelcap and a deeper tunnel. Hell, why do things the easy
way when there is also a hard way? I started by completely
removing the bottom of the tank, then cut the top part
to size untill the bottom of the tank was horizontal.

 

This looks about right...

 

My buddy Aad, who is a better welder than I ever will be, cut and grinded a round
piece of steel to fill up the hole left behind by the old fuelcap. He started with two very
small welds left and right, and then carefully started adding small welds in a crisscross
pattern to prevent the metal from warping because of too much heat.

 

After the weld was completed the outside of the tank was ground smooth.
The removed bottom of the tank makes this whole operation a lot easier
because we can now easily weld the inside.