1st Post! Chopper Tank Install

[TwoWheelThomas]

Hi everybody! I’ll be installing a new mid-tunnel chopper tank on my 75 xs650 this week, and was wondering how much trouble I should be expecting with a tap and die job. Any help is appreciated! Thanks!

 

[miketweedie]

Not sure how you plan to mount it, but for mine I bought the threaded top hat inserts from Lowbrow. Drill the holes where you need them and weld them into place. Very straightforward, just be sure to thread a bolt into it before welding to keep it round (and also prevent any welding splatter from landing in the threads). The bolt also makes it way easier to keep it straight when tacking it into place.

https://www.lowbrowcustoms.com/products/tophat-blind-threaded-aluminum-bung-3-8-16-thread

 

[jpdevol]

These steel bungs in 5/16 thread maybe and some leather washers

https://www.lowbrowcustoms.com/coll...phat-blind-threaded-steel-bung-5-16-18-thread
https://www.lowbrowcustoms.com/prod...16-inch-hole-1-inch-diameter-x-1-8-inch-thick

 

[miketweedie]

@jpdevol yup those are the ones. I will admit I didn't even look at the size when I grabbed the link!

 

[jpdevol]

how much trouble I should be expecting with a tap and die job.

IMO, drilling/tapping the frame backbone w/o weld-in bungs is not substantial enough: the tubing is only ~.125" wall thickness

 

[TwoWheelThomas]

Not sure how you plan to mount it, but for mine I bought the threaded top hat inserts from Lowbrow. Drill the holes where you need them and weld them into place. Very straightforward, just be sure to thread a bolt into it before welding to keep it round (and also prevent any welding splatter from landing in the threads). The bolt also makes it way easier to keep it straight when tacking it into place.

https://www.lowbrowcustoms.com/products/tophat-blind-threaded-aluminum-bung-3-8-16-thread

Thanks! I was hoping to do a tap and die and avoid welding since I don’t have access to a welder, but if it doesn’t work out I’ll definitely hit up Lowbrow. They’ve worked out great so far with other purchases

 

[jpdevol]

Thanks! I was hoping to do a tap and die and avoid welding since I don’t have access to a welder, but if it doesn’t work out I’ll definitely hit up Lowbrow. They’ve worked out great so far with other purchases

I've not used them in this application, but there is a "no weld" alternative: Rivnuts

https://www.mcmaster.com/products/rivnuts/steel-rivet-nuts/ .......might require a special tool to get it right in your case