EN500C Gas Tank Re-size

[Jablonsky]

Fuel tank capacity of my Magnus is one of the few things I'm not happy with. So I decided to start a project, basically like THIS ONE, though a bit more complicated due to the shape of the EN500C original tank. Obviously, I am not doing it myself. My welding skills are so poor that I might get out some kind of a gigantic flatworm instead of an increased tank. And I really wouldn't know what to do with a flatworm. The beast might even be dangerous.

I clicked a cheap (and also dented, but who cares?) tank off ebay.




The idea is to cut it open roughly along the marked lines and insert additionnal 3 inches on each front side. I haven't even tried to calculate how much capacity I could gain, but I hope for a substantial increase, bcs most of the volume is in the front end of the tank.

I also hope the guy who is in charge of the whole welding business knows what he is doing. His references are excellent and he looked quite self confident yesterday during our meeting. If half of the guy's reputation is justified, I expect Magnus to become an impressive machine. Might even run for the next Governor of California.

I'll be back.

[fastpakr]

I'll be very interested to keep up with this. You don't think it will be too uncomfortable sitting around it? Any cost estimate?

[burkbuilds]

Great idea. I hope this projects works well for you. I'm sure a lot of folks will be interested in your final results both how it looks and how much capacity you gained. Good luck!

[Jablonsky]

Glad you like the idea. I really dislike to have so limited range and I discussed all kinds of possible solutions with my friends.

...You don't think it will be too uncomfortable sitting around it?...

I am sure it will not be uncomfortable.
First: the rear part of the tank remains unchanged and it opens only towards the front end.
Second: I've tested it by putting small pillows between my knees and the original tank. No problem whatsoever.

...Any cost estimate?

It won't be as cheap as one would wish. I think I'll spend abt 300 - 350 $ for the tank + all the work (cutting, welding, mending the dents, paintjob...). There surely are ways to save some money, but I want it to be done well by experts. In long term, cheaper solutions often turn out to be more expensive.

[Triangles]

300 - 350? is that USD? that seems very reasonable. I've eyed some raw unpainted "custom" Harley/chopper tanks that I've found relatively cheap. Only problem I have is that I don't want to spend the money unless I'm certain I can make it fit.

[Jablonsky]

300 - 350? is that USD? that seems very reasonable...

Obviously, reasonable enough for me to start this project
And even if it comes to 450$ and the thing works as I expect, I won't complain.
Just today there was another guy, offering a lot less for close to 700$. And I am lucky, bcs I already made the deal yesterday. Otherwise I would have to think about his offer

Keep your fingers crossed for Magnus and ol' Jablonsky

[Jablonsky]

Progress report:







From where I seat it looks like our team could be winning

(Would anyone like to guess/calculate how much capacity we will gain? Burkbuilds? Maths was never my favourite subject )

[Triangles]

I'll start the bidding at 5.2 gallons

[fastpakr]

I'll take 5.5.

[burkbuilds]

I'll guess an extra gallon, so about 5.0 gallons total. But I hope you actually get a lot more than that.

[Jablonsky]

Progress report #2:





So far, so good (I guess).

[Triangles]

the correct capacity guesser wins the tank right?

[Jablonsky]

the correct capacity guesser wins the tank right?

Of course. Why else would I have started the whole project if not to give the tank to the lucky winner?

[kawboyCAFE]

i'll say 4.75 gallons.

[burkbuilds]

Hey Jablonsky, what's the latest update on the new tank? Is it finished and installed yet? What was your final capacity? Do you like it, did everything fit the way you hoped? Hope you have just been busy riding and enjoying the longer range of the new tank and haven't had much time to post, but let us know.