Tunnelling & Mounting a Wassell Tank - What's involved?

Hummingbird

Active Member
Hey people,

I bought a Wassell tank for the SR250 and now realise it requires much more work than I initially expected.

Some expert tank fabricating advice will be very much appreciated.

Ingredients I have:
- Wassell Tank, British fuel bung, 1/8" Triumph/BSA styled petcock
- SR250 Tank
- Daytona Fuel Cap

Ingredients I don't have:
- Screw Bung for Daytona Fuel Cap
- New Petcock
- Seat mount

Here's what I think I need to do, but please correct me if you would do it another way.
- Widen the tunnel by 2 cm to allow the flush C shaped mounts with the rubbers.
- Weld on a new fuel bung.
- Find a 1960's petcock and reattach it.
- OR Patch up the petcock area (because the Wassell petcock sits too far back) and transfer the stock petcock over.
- Weld seat mount probably transferring part of the stock mount over.

I need expert help because if I stuff up, I'll have destroyed a previously immaculate SR250 tank that will have huge holes where the mounts used to be and a possibly destroyed Wassell tank with all the niceties missing like bung, petcock, vintage brazed mounts, and that branded tunnel. Not good! haha

See original thread: http://www.dotheton.com/forum/index.php?topic=9930.msg235522#msg235522
 
I'm not a lot of help here, but could you shave the rubber tank mounts to fit inside the tunnel instead of widening the tunnel?
 
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