Rubbermount_EVO 04-06 metal oil tank

[SJoyce]

khaskins I've done almost everything I want to do with my bike beside's stuff that cost over a grand each (like tripple trees and air suspension, which are both things I want to do). My winter project was making a new 8.5 rear fender fit so I can run a 180 tire (waiting for my current tire to wear down now before getting a 180).

I'm cheap and like doing different stuff for fun. I picked up an oil tank from ebay for 99 cents + shipping from a 99 Sportster and I think I will start moding it in the next month or two when I pick up some more welding gas.

The reasons I'm starting out with an old oil tank is that it appears to have a similar shape oil tank that will fit under my 04 chrome side cover to keep my leg cool on long trips and the reason why I really want a metal oil tank is so I can make it into a shape that fits the most oil I can on the right side and on the left side of the bike I can make a lockable storage box beside my battery.

[SJoyce]

Good news and bad news for those who would like a metal oil tank for a rubbermount Sportster.

The good news is that is possible and you can get alot more oil to fit in the wasted area Harley created by using a crappy plastic oil tank.

The bad news is that the more you want your bike to keep the same look as the rubbermounts the more work it will take.

First off before you start this project be ready for it to not be a single weekend project.
I lost a couple of good riding days due to the weather man being wrong because of the time it takes to uninstall/reinstall the factory plastic oil tank, you have to take off your battery tray, electronics under the seat, belt guard, rear brake fluid reservoir, and obviously drain your oil to get the tank out.

I started with a 99 Sportster oil tank from ebay and was able to make it fit with a hammer and cutting off the mounting tabs, but I wasn't satisfied with the battery tray and side cover not fitting like factory. To make everything fit the way I was wanting I had to cut the entire inside of the 99 oil tank out and weld in new metal along making new mounting tab and mounting points. I was able to fit a little over 4 quarts in the tank as pictured but I’m still deciding on making it fit the 3.6 quarts similar to stock or not (to make the tank smaller for a larger storage spot for small things like spark plugs...) I’m using the same three mounting points as stock, and when all put together with the side covers on it looks just like stock when bolted in which I LOVE. (except for having to use a 2003 dip stick)

Benefits of this project
+ Storage area can be built (Idea for those with EFI computers)
+ More oil capacity for cooler temperatures
+ More room for extra electronic under seat
+ More room for custom fenders
+ So much easier to install and reinstall the tank I built (but once done useless)
+ Less plastic crap

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I have some questions before I can finish this project though

What is a good sealer you have used to seal the inside of your oil tank with or should I just pay a radiator shop to do it? (When I called the different radiator shops around me the only one who said the could do it said it would cost $135 (is it just me or is that high?))

I'm relocating my fuses to be on left side of the battery similar to the 2010 Sportsters anyone have any pictures of that style fuse block holder?
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[manman]

Originally Posted by SJoyce

I started with a 99 Sportster oil tank from ebay and was able to make it fit with a hammer and cutting off the mounting tabs

Oldish topic, yes, but...
Does it fit by just relocating the mounting tabs? What did you hammer?
I don't care, or actually don't want, to put on the '04 side cover.

Why? I hate the difficult to operate oil filler cap on '04s.

[Folkie]

Originally Posted by risotteria

04-06 metal oil tank

Has anyone come across a direct metal replacement for these years plastic oil tank

Or even the completely different 07+ oil tank.

[BestCoastXL]

Reviving this thread.

@slimsfab on IG has metal tanks for Sporties.