Our friend Theo is restoring a Harley Davidson W from 1919, this has a rather rare boxer engine. The engine is already rebuilt but the tank was still missing, so we will be making a new tank from skratch.

PART 2

After making some neccesary tools las week, Aad made a lot of progress on the tank. After roughly hammering out each piece with a wooden hammer on the sandbag, each piece is smoothed with the planishing hammer untill the tape template fis perfectly.
then the edges are trimmed and beadrolled using he tools we made last week.

The pieces are tackwelded together, the tackwelds are ground flat and then a copper strip is clamped against the inside of the tank, covering the gap. Then the gap is welded with TIG from the outside, the copper strip prevents burning through and saves you a lot of time cleaning up the weld.

The right tankhalf contains an internal compartment for the oil, this has been pressure tested to make sure it does not leak. The right half of the tank is now mostly finished, the last step will be soldering the 2 halves together, that is what the "lip" in the last picture is for.