Sturgis Rally
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Remember back in the good old days when stretching or customizing a motorcycle gas tank involved cutting and welding, not to mention the requisite skill involved with performing those actions. Not only was one required to violate the basic gas proof integrity of the stock tank, that gas proof integrity was often very hard to restore. A substance called "Cream" could be pored in the gas tank to coat the interior of the tank to offset any poor welds,. Or pin holes. Altering of customizing a gas tank in the past was a pain in the behind, and took far too much time away from riding to be worth the effort.

These days, thank to John Shope at Sinister Industries, and others, one can starch a gas tank in about 30 minutes. Custom tank covers have taken most of the danger and labor out of stretching or customizing a gas tank. Using a John Shope's Sinister Industries tank cover set, the job can be performed in as little as 30 minutes. Watch it happen here in a sequence of photos. The procedure as seen here was performed by persons very experienced in the process, and they make it look easy. And it is actually very easy procedure with a little practice. 

John Shope’s Sinister Industries tank covers halves prior to installation on a stock Harley-Davidson sheet metal gas tank.
The stock gas tank has had ALL the openings sealed to keep unwanted dirt and debris from getting inside during the tank stretch.
The gas tank is sanded to remove all the existing paint at the all the contact/glue locations.
The sanded gas tank looks ugly huh? Solid tank cover adhesion is required at the sanded points and removing the paint makes that possible.
The tank cover halves must be thoroughly cleaned with acetone to remove the mold release compound prior to gluing the covers to the tanks.
The Sinister tank cover halves are then sanded at all the locations where glue will be applied.
Prior to the application of the adhesive, the covers are subjected to a final check fit with clamps.
These tank covers are a perfect fit, the adhesive can be applied.
The clamp is removed and the tanks and covers are given a final wipe down.
The adhesive is now applied to all the surfaces that have been prepped.
The applied adhesive is now spread evenly on the prepped surfaces. Gloves are required.
The tank halves are quickly fitted to the gas tank, then clamped.
Duct tape is utilized as needed to keep pressure on the tank covers as the adhesive cures.
The adhesive will be allowed to cure for 24 hours before the clamps and tape is removed.
This gas tank has had the John Shope Sinister Industries tank covers and dash treatment as well as the appropriate body work and paint.


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