okay, backlog of work to document here. I've been busy with finals but i did manage to sneak a few minutes in to do some work on the bike. I'm pleased as punch with what I accomplished, so here's a run down.
Removed the carbs and gave them a thorough cleaning. They weren't that dirty, but i got in every nook i could. Before I reassembled them, I adjusted the floats. Then I tested them by blowing into the fuel line and slowly turning them upside down until the flow cut off. After I got them back on the bike the left carb will still flood and leak if i don't shut off the petcock but only if it let it sit for a few minutes. Neither are pissing all over the engine like crazy, so I will count that as a win. especially for the cheap ass pwk carbs that they are. I've decided once I get the bike healthy I will get a vm34 kit from hoos racing or somewhere. whoever has the best deal really.
Next up, the tank. So I was very excited to get the tank on after getting it running just using a small amount of fuel line filled with gas. I get everything plumbed up with the vacuum petcocks and dumped in some gas. I started it up and went to the gas station and back and the bike was running like a pig. I decided to look into rebuilding the petcocks but quickly changed my mind. A rebuild kit it cheap enough, but since I didn't plan on keeping the tank I figured I'd go ahead and order the tank I'd been pining over. (the xs750 tank will be for sale as soon as i can find a box to ship it in.)
Enter stage left - Lowbrow Wassell Tank.
Very solid, very thick, very cheap. I ordered the tank, a cap, 2 petcocks, set of tophat bungs, set of leather washers, and a new throttle so i can ditch the old cluster. They were kind enough to include a bag of peanuts.
I couldn't get this on there quick enough! It did take me a while though. I took off my top motor mount and threw it in the box of leftover shit. Luckily enough HHB was having a birthday sale so I got a new (non-windowed) upper motor mount at a discount! Go me! Unfortunately I didn't get very many pictures of it as it will be a small visual component.
When I finally got a weekend for the project i jumped on it. Here's a pic of the test fit/placement.
Just barely fit in every way possible. Just barely above the engine, just barely on the straight parts of the backbone, just barely wide enough. I'm not sure if it's luck or what, but from here on out I'm calling it "precision."
The process from here was pretty straight forward but challenging. I centered up a leather washer where it needed to be on the mounting tab and used a centerpunch. I bought a centerpunch specifically for this project and i'm glad i did. I put the tank in the final position i wanted it, drilled a pilot hole in the tab and then through to the backbone. Once this was done I removed the tank and used a stepper bit (also purchased for this project) and drilled it to accommodate the bolt+paint+breathing room. Then i used some motor oil and the stepper bit to drill into the backbone. Point of no return, there's now a giant hole in my backbone.
Once this was done I assembled the bung, bolt, and leather washers onto the tank and fit it into the hole i just made.
I had to do a little extra work with a file to get it to fit, but when it fit, it was snug.
Since that was holding the tank firmly in place i could move on to the rear mount. Repeated the same process. Punch, pilot, step, file, test fit.
Here's the final test fit before welding.
And the holes.
This looks incredibly sketchy, but after the bungs are welded in it should be stronger than before. Also pictured: HHB upper motor mount. At this point i used a paint stripper thingy from advance auto and prepped the area to be welded. I also used a set of files to deburr and clean up the holes.
Unfortunately I didn't get a pic of the coolest part because my welding room is tiny and having a bike in there had me in compromising positions. I also had to do some shaping to the top of the bungs to match the mounting tabs. Here's a pic of the tank loosely bolted on.
Another thing to note is that i found two random (properly sized) bolts from other projects and used them inserted to keep the threads from warping. I placed two tacks, front and back, check straightness in all directions, two more, left and right, check straightness. weld 1/4 jump to opposite side and weld another 1/4, jump to opposite side again and weld 1/4, jump to final side and weld final 1/4. repeat for other bung. Left it to cool for a bit, rolled it out, taped it up and used a self etching primer and high heat gloss black to repaint the backbone. I also used the scrap bolts for this process to keep paint out.
HHB upper motor mount clearance
I did get a jam nut to bolt the top of the mount on, however it was still too wide. I imagine if I moved the tank back a bit it might've fit better, but i just took a flap disk to it and took off little by little. Then i used some loctite and cranked that bitch down. Keep in mind the wiring will be cleaned up eventually.
Pt. 2 will be posted in a minute.
. i've dropped a desire for a pma kit now that i know the tci works. i keep hearing about how awful these carbs are, what are my options for aftermarket? also the brakes are functional but will have a complete flush, pad change, and thorough test before it gets on the road. i've lost brakes on the road before and i'd rather not do it again. 
