FZRSupport: the FZROnline Archive

I would like to make a fuel tank for my FZR 1000 to go underneath the steel tank. I know that means chopping out the tank that is already in it and making it a cover. Has anyone done this as a project and what did you use for a guage of aluminum? Where can you find a generic fuel filler or should I just have an aluminum flange made up to refasten the existing cap and latch to? PLease advise.

Sounds pretty whacky to me.
Can I ask, why you would want to do this?

Well its kinda like this, more capacity, Aluminum doesn't rust, can drop the fuel tank bottom lower between the frame rails to drop center of gravity, tank cover wouldn't need to be on to tune carb's cause the tank would be in the bike not on it. Those are my reasons, and I saw a picture on modking's add for coolant tanks for sale and thought that more than just his bike had been done up this way. Hope that explains my nutty idea.

That sounds fair enough.
Difficult job to do properly. Will cost ALOT unless you do it yourself. I sometimes do this sort of thing at work unfortunately. Id go for 1.5mm - 2.0mm ali.
I don't see how you will be able to increase the capacity if you want carbs uncovered.
If it were me. I would chop the bottom bowl out (or there abouts) and redo it in steel. And line the tank with caswells or por15 epoxy. Its good shit, ive used both.
As for tuning carbs, just remove tank. Hook up a clear PVC tube about 25mm diameter by 1meter long or so with plastic reducers at bottom and funnel at top tied to garage rafters or whatever. Just top up as required. all available from hardware store for a few bucks. Its not like you tune carbs that often. Don't smoke cigarettes while performing this procedure
My 2 cents.

sounds fair enough, lucky me I don't smoke, I will likely try to build one but I have a buddy in plastics manufacturing and he gave me the low down on how to make a mold and then attempt to cast one from fuel resistant poly.Again likely a silly idea as no-one will be rushing to my door for one but at least i will have a one off part and I won't spend hours hammering aluminum into the shape of the recess behind the tank body. Good point on the tuning as well once it's done I should not have to mess again for awhile.