Gas Tank Knee Dents & Gas Cap Install

Another typical cafe racer gas tank modification is putting knee dents in the factory gas tank.  The purpose of knee dents is to slim up the rear of the tank and have a place for your knees to grip better when cornering.  Follow along here as we fabricate the knee dents and install a Lossa Engineering billet custom gas cap.

 

Start by sanding all the paint off of the area where you are going to put the knee dents

 

 

Mark both sides evenly up to where you are going to make the knee dents.

 

 

Using a nylon mallet, slowly start hammering around the perimeter and work your way around the outside of the pocket.

 

Fine tune the edges with a little sharper hammer end.

 

Sand the area around where the gas cap bung will be installed. We wanted to keep the factory splash guard and overall strength of the top of the tank, so we did not cut out the factory stuff

The bung was a little tall, we cut it down in the lathe before we welded it.

It is good practice to have the gas tank lined if you do any fabrication or welding on it.  Also, most tanks this old have rust and debris inside, so it is a good guarantee once your expensive paint job is done, you will not have any leaks and blow out your paint.  Any debris or rust left in tank will make its way into your carburetors and clog them and cause more serious problems.  After it is sealed, bodywork the knee dents with some body filler till they are nice and smooth, Primer and then Paint, Done!

Welders by Lincoln Electric

Metal forming and Shaping tools by Woodward Fab

Install by Lossa Engineering