950/990 Adventure/Gobi's rack mod for the ADVTANK

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by a$$hole, Jul 30, 2010.

  1. a$$hole

    a$$hole Long timer

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    Many people have said its a real PITA to get their gas cap off of their ADVTANK after it expands. I personally couldn't get the cap off at all and not using the tank was killing me. So I had heard of someone cutting off the bars and flipping them around and re welding them so that you could get to the cap. But I had never seen a write up about it and thought I would show some pics of how I did mine. This isn't going to be a step by step how-too but just some pics and a brief explanation of what to do. Hopefully it helps someone out!


    First I took off the racks and bolted them back together on the ground so that everything would stay in alignment. Then I used a cutoff wheel too cut the top two rear bars off.
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    Next I flipped the bars around and fitted them with a 90 grinder to there new locations. I had to trim off like a 1/4" to get them to meet up equally on both sides. If you have a torch I would bend them a little bit so you can keep your stock turn signals. Otherwise you might have to get some small LED's like I did.
    [​IMG]


    Then I simply took them to the local welder guy and had them zipped up in less than 5 minutes for $20. Although he tried to only charge me $15 after he found out I was a welder just like him while in the Marines:deal . But I instisted on the original $20 price. They turned out really nice too.:clap
    [​IMG]



    After welding I just stripped them down and used Rust-Oleum semi-gloss black paint and that was it. You can see how the factory blinkers kinda get blocked by the new bar placement. Although they do fit better than new and bolted right up with no problems with tons of room to get the gas cap off now!:clap
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    #1
  2. ganshert

    ganshert not sleeping

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    brilliant!

    thanks for the great idea
    #2
  3. pebble35

    pebble35 Long timer

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    I have the same problem - thanks for sharing your solution !

    Racks coming off tomorrow....................

    :clap :clap :clap :clap :clap :clap
    #3
  4. a$$hole

    a$$hole Long timer

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    It really is pretty easy. And it looks great too! No more having to fight to get the cap off.:clap
    #4
  5. crazybrit

    crazybrit Long timer

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    Hmmn. Rather than flipping both tubes around (which blocks the turn signals) would it not be possible to rotate the left supporting tube (red arrows) and weld to the existing rack tube (yellow arrow) so that it's right behind the turn signal.

    This should give enough room to get the cap off, no?

    I was thinking of just doing it on the left side. It won't be symmetrical but that doesn't seem like a major issue. I'm taking a TIG welding class right now so it seems like a good project :D

    Comments?

    Attached Files:

    #5
  6. Just Paul

    Just Paul Pro Cat Herder

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    thanks for this post.. Mine turned out great.. I also added a brace because I bent the bracket and the tank was rubbing on my tire..

    [​IMG]
    #6
  7. crazybrit

    crazybrit Long timer

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    did you use a$$hole's method? I can't really tell from your pic. It doesn't appear that your turn signals are blocked .... but I'm not really sure how badly they are blocked as a$$hole's pic is taken from above rather than from the rear.
    #7
  8. dad2bike

    dad2bike Retired! Cranky Old Fart

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    My post in another thread.
    #8
  9. crazybrit

    crazybrit Long timer

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    thanks for the pic. so basically same as what I proposed a couple of posts earlier, thanks for confirming it wasn't a bonehead idea :lol3
    #9
  10. Just Paul

    Just Paul Pro Cat Herder

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    I used the same method
    The brace came first
    Then the pic taken
    Then I did the gas cap mod

    Mine looks the same
    #10
  11. crazybrit

    crazybrit Long timer

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    Do you have a recent pic from the rear? If the one from before is before the mod, it's not that useful :D I'd be curious to see how badly the flipping/gas-cap mod is in terms of blocking the turn signals. You can't tell from a$$holes post.
    #11
  12. Kenbike

    Kenbike Been here awhile

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    Just installed a tank on my 990 and cut and rewelded the bracket so it was just a 1/4 away from the turn signal. Worked great went to the station and the new tank held 2.27 gallons. Went for a hour test ride and when iIgot home smelled gas, turned around to look and found I had not put the aux tank cap on:asshat
    #12
  13. FORE!

    FORE! pretender

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    If you need another cap - we have them in stock.

    Scott

    #13
  14. Kenbike

    Kenbike Been here awhile

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    Scott, luck was with me. the vent hose held the cap on the bike so I just put it on. PS the instructions with the tank are very hard to read or make out what is in the photo, with out this how to install guide I would have had trouble.
    #14
  15. Jonny955

    Jonny955 Been here awhile

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    I'm thinking seriously about fitting the ADV tank to my 2012. I have the 'quick detach' SW Motech racks and Gobi panniers, not the fixed older type tubular racks for Gobis.

    Has anyone tied this combination and if so, can you get to the filler cap?

    Thanks in advance.

    Jon
    #15