How would you do this? (gas tank modification)

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Hey, i saw this idea on another forum and it caught my interest.the idea is to cut and weld the bottom of the red tank on the purple tank. Now what i would like to know is what would be the cutting method of choice to keep the shape of the tank without ruin it and what would be the way to weld it tight without leaks, mig, tig? This tanks arent aluminium and they are rather thin i would guess 2mm to 3mmJust to clarify i dont intend to do this, just would like to know  some ways of doing a project like that because who knows right?
Reply:I'd use a zip disk (thin cut off disk) and oxy / acetylene weld it.Lincoln SA200's... at least 15 - 20. They come and go. Growing partial to the "Short Hoods" in my old age. Last count on Short Hoods was 13 in possession.
Reply:zip disc and braze it if you can cut it so the two overlap some. othewise tig it or OA weld.
Reply:If either tank has had gas in it already..myself....I would STAY AWAY..FAR AWAY....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Well yes i agree not just about anyone can work on a gas tank but it can be done, there are people who do it for a living. I for sure wouldnt try it now.Interesting it can be done with oxy welding, i guess it would require a small torch and some skill to not distort the whole tank with heat and to get a leak free weld. thanks for the replies.
Reply:If either tank has had gas in it already..myself....I would STAY AWAY..
Reply:What sort of solvent would they strip it with?The solvent is probably as flammable as gasoline, although it may evaporate quickly and completely.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Thin kerf Zip disc, TIG,  I think Oxy will warp and distort it quite a bit. What is the purpose of the swap, The way it fits the frame, more capacity, damage? fuel ports? might be easier to mod the bike frame."Si Vis Pacem Para Bellum"Lincoln Idealarc 250 AC/DCMillermatic 251   Syncrowave 300   30A spoolgunLincoln MP210Hypertherm 45(2) LN 25(2) Lincoln Weldanpower 225 CV(4) SA200   1 short hood    SA250    SAM 400
Reply:The purpose of the swap is to make the purple tank fit on a bike it wasnt made to fit. Modifying the bikes frame is easier except that it would have to cut a cross section that would need to be replaced somehow. I have heard of several ways to make a gas tank weld safe, using fire extinguisher powder, exhaust fumes, water, etc. but which are truly safe and which arent i just dont know.
Reply:Originally Posted by kolotThin kerf Zip disc, TIG,  I think Oxy will warp and distort it quite a bit. What is the purpose of the swap, The way it fits the frame, more capacity, damage? fuel ports? might be easier to mod the bike frame.
Reply:What sort of solvent would they strip it with?The solvent is probably as flammable as gasoline, although it may evaporate quickly and completely.
Reply:"caustic" is probably sodium hydroxide.  Non-flammable and not a worry, if that's what they're using.  I've seen engine rebuilders dip blocks into heated solutions of sodium hydroxide and water.  Cleans the oil and gunk right off.  I never thought about what it would do to paint.  Probably depends on what type of paint.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:If you must cut on that tank at least rinse it out with water then refill with water plug it up then work on it. the less air you have in there the better off you are.
Reply:I generally agree with filling it with water, but don't plug it.  It's going to be near impossible to completely fill it with water.  Any remaining air could still support combustion.  If you have it plugged that could still be dangerous.  If you have it open, then the relative small volume of trapped air compared to the size of the opening should just get you a 'huff' if anything ignites.Dynasty200DX w/coolmate1MM210MM VintageESAB miniarc161ltsLincoln AC225Victor O/A, Smith AW1ACutmaster 81IR 2475N7.5FPRage3Jancy USA1019" SBAEAD-200LE
Reply:Get a can of red spray paint and paint the purple tank red,  Sheeh, why do people make things so difficult??Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:zap, really? A little tank job would scare you off? That makes me kinda giggle. There is a safe process for almost everything. And then there are guys who just get the job done. No need to put yourself at risk. Just find a guy willing to do it himself. lolLincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Its just a little gas tank . It should be ok. I have welded quite a few over the years from trucks to motorcycles. thats the way i always done it . Fill with water, put on gas cap or plug up,turn on fuel valve if there is one and get to cutting .I use a wafer wheel . There is not going to be enough pressure to do any thing as long as you take the gas out first LOL. My grandfather showed me that way about 22 years ago. He is 82 years young and still welds them that way. (dont try this at home) when I was young I would help him weld live gas pipe lol. He would take a flex dryer hose and put it on one end of the gas pipe and the other on his truck exhaust pipe and weld away .
Reply:I've welded and brazed small tanks for generators and such... I wash out the inside of the tank with denatured alcohol.  Any gasoline residue will dissolve in the alcohol solution, and after draining the tank, the alcohol rapidly evaporates when putting a decent air blower through the tank.  For added peace of mind, once dry, secure the tank and use a long handled propane weed burner to provide an ignition source to the mouth of the filler.  I've never had any flammable vapors left to witness a pop.
Reply:Dipping avoids the annoyance of removing the paint by getting most of it for you. I'm lazy, so I prefer it. Bike tanks in the age of ethanol usually have nasty deposits which dipping removes.