If you are not a highly skilled sheet metal worker you are going to have problems.It would be better to buy one and modify it if you are going for a certain look. There are so many choices when it comes to custom tanks that I'm certain you could find one that would suit your taste. If you are set on doing it yourself you have to start somewhere.Good Luck.How do I make a gas tank for a motorcycle out of sheet metal?
You don't. The ones you see on American Chopper are the worst crap ever built. They all leak and fall apart as soon as they start using them. Making a tank that can take the expanding and contracting and flexing a gas tank needs to take isn't something to do in your garage.How do I make a gas tank for a motorcycle out of sheet metal?
Hammer to shape, File to fit, Paint to match.
The easiest way, if you've never done it before, is to pay someone else to do it for you.
It can be done, but you had better be a good welder and you will probably want to round out the halves of the tank on an english wheel before you weld it. Watch Orange County Chopper and similar shows. I think it would be easier,cheaper and better to buy a new one or to search around a motorcycle wrecking yard for something suitable.
Watch American Choppers on TLC... they do it all the time... if you know how to weld you can do it
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