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  #1  
Old 2nd August 2009
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Default Super Glide Tank Conversion Illustrated

The goal here was to increase range, provide a fuel gauge and not have to cut/drill or damage the bike or tank in the process. This makes the mod reversible if needed.

The Tank: 2006 FXD Super Glide
I was specifically looking for a late model tank from a Super Glide because I like the center fill and the aviation style gas cap and gauge set up with the wrinkle black console. The HD chrome console upgrade will also fit these tanks. I found e-bay to be the best source for used tanks. Most of the ones that are priced right need a little work/paint etc.
This tank cost me about $160.00 and had a couple of dents, but it was the same color as my bike so I bought it and managed to massage the dents down to very small dings working them from the inside (Later plans include a paint job anyway with a ghost black flame so this worked for me).

Mounting the tank was a matter of “extending” the mounting holes on the bike to meet the location of the new tank mounting flanges on the tank. (This is actually not much different then installing tank lift kits that are sold several different places for riders that want to rake the front of their tanks).

Here is a list of some of the parts I used:

06 Dyna Super Glide 4.8 gallon tank - 61590-04 (A bit more without the fuel pump)

Tank Top-Plate assembly - 75243-04B For carbureted Super-Glide tank
Assembly includes*
*Fuel restrictor kit - 61115-04A
*Filler Cap - 61553-04B
*Filler Cap o-ring - 61030-04A
*Pin Housing - 72904-01BK
*Seal, top plate - 75245-04

Fuel Sender 75219-04

Tank petcock adapter 62912-04

Top Plate Screws 1331 (12 each)

Fuel Gauge Kit 75001-04

Console, wrinkle black - 61692-04

Golan Petcock (forward facing) - 76-312F

Trim Ring Back Mount – 61545-04

Fuel Gauge Mount Ring – 61499-04

Plug Wires used – P/N 31907-08 (Two Sets – See note below)
Note on plug wires:
You will need 45 or 90 degree plug boots to keep the rear plug wire away from the fuel valve. Magnecor (http://www.magnecor.com/) can make up whatever you want and that was going to be my first choice, but I ran out of time. I found a set of Soft-tail Screaming Eagle 10mm wires that had one wire in each set that would work, but the other was too short. I ended up buying two sets just to get the two wires I needed with a 90 degree plug boot.




The mounts were made from 1"x 3/16" bar stock.
The front mounts were cut 5" long with 4" hole to hole. Then heated and bent with a 3/8" offset.
This puts the holes at 3-7/8" after bending.
The top part of the mount needs at least 3" before the bend for clearance.
The mount was then trimmed on the aft side to provide better clearance for the tank and the corners got a radius. The upper hole is 3/8" and the lower hole is 5/16"

The rear mounts are made from the same stock cut to 1-3/8" in length with 3/4" hole to hole. The holes are 5/16"

This is a shot showing the difference in mount locations and illustrates the gap that the mounts need to bridge.

[IMG][/IMG]

Front Brackets in work. The bracket on the left has been cleaned up and trimmed on the aft edge to provide some clearance for the tank when installed.

[IMG][/IMG]

Front bracket bend needs to start at 3" from the top to clear the tank mounts.

[IMG][/IMG]

[IMG][/IMG]

These are the rear prototype mounts installed. I was trying out different measurements.

[IMG][/IMG]

Mounts primed and painted. I used a “Tractor Implement” paint from Tractor Supply for durability.

[IMG][/IMG]

Here are the mounts in place on the tank (I recommend not installing the mounts until the tank is in place. These are installed to illustrate their position).

[IMG][/IMG]

[IMG][/IMG]

This is an illustration of the console assembly. This will come in handy when putting the console together or making sure you have all the parts you need. The Top Plate #10 comes with most of what you need if bought as an assembly P/N 75243-04B (See parts list).

[IMG][/IMG]

Bottom of top plate with sender.

[IMG][/IMG]

The top of the plate showing the vent line connection. The tank vent line on the bike needs to be extended and then reduced in size to fit the top plate. Reducers are sold at automotive parts stores.

[IMG][/IMG]

Top plate screws have seals on them to prevent leaks from the base plate.

[IMG][/IMG]

The fuel sender and float

[IMG][/IMG]

Here are some shots of the sender in the tank. The sender is installed by positioning it on the center hump inside the tank (Float on the right side of the tank) just aft of the clips. Then push down and slide forward to lock in place. Once installed route the wire under the tab shown in the picture below and bend it down just enough to hold the wire in place.

[IMG][/IMG]

[IMG][/IMG]

This is how I wired the gauge. You should notice that the sender potentiometer is on the ground leg. I opened up the instrument harness that runs up the left side of the frame neck. It can be unplugged just aft of the coil and pulled clear which makes it easy to tap into. This is where the orange instrument power wire and the black ground wire that you need to splice into are located. Double check the ground line. Do not assume that if it’s black it’s ground! (Don’t ask me how I know this). Add a connector to the harness for tank removal.

[IMG][/IMG]

Mounting the tank.

I used the aft console mounting bolt to fine tune the seat fit. The longer the bolt was, the more room I had for the tongue of the seat to fit into. As this got raised it also moved the tank back slightly as the aft mounts changed angle. When I got it just right I simply tightened the bolts on the mounts. Once the mounts are tight there is no load on the bolt, but I also added a rubber cap just in case to prevent damage to the frame.

[IMG][/IMG]

Seat Tongue

[IMG][/IMG]

Button head bolts work the best for the front mounts to avoid any clearance issues with the triple tree.

[IMG][/IMG]

[IMG][/IMG]

The cross-over line is routed in front of the coil. It's a tricky fit, but I used the original fuel line from the carburetor to the 3.3 tank and was able to take advantage of the bends that were molded in it from the factory. A straight piece of fuel line will work; I just liked the bends on the original.

[IMG][/IMG]

Screaming Eagle wires and Golan petcock.

[IMG][/IMG]

Done!!!!!!!!

[IMG][/IMG]

[IMG][/IMG]





Over all it was not a bad mod to complete. My goal was to mount a Dyna Super Glide tank without having to cut/drill/weld the bike or the tank. I managed to pull it off and I am happy with the results.
I like having 5 gallons of gas, a gauge and the look works for me.

There seemed to be a lot of interest in this type of mod so hopefully the information helped somebody out that may be considering a tank conversion. This is certainty not the only way to do this and I am sure many can improve on the work.

Well that's all folks... Hope you enjoyed the write up.

Last edited by bplinson; 4th August 2009 at 20:25.. Reason: Fixed img tags
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  #2  
Old 3rd August 2009
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That looks great. I might have to try that with a Softail so I can move my speedo.
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Old 3rd August 2009
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Man, what an informative thread! You should be writing technical papers. Seriously, you did a great job on the conversion. Looks pro.
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  #4  
Old 4th August 2009
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Awesome write up. Do you know if this will work on a pre '04 also??
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Old 4th August 2009
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Great write up! Have some rep.
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Old 4th August 2009
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This is triple-A write-up stuff.
Lots of talented people here, and you're certainly one of them. Have some well deserved rep.

Edit : Have spread a bit to much rep around the last 24 hours, I'll get back on that
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Old 4th August 2009
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Quote:
Originally Posted by bplinson View Post
Awesome write up. Do you know if this will work on a pre '04 also??
I can't say for sure without taking a close look at the 03 mounting, but the process should be the same with a few different measurements and some tweaks to the mounts shown above.
It would be interesting to find out.
Maybe I can get a local 03 to look at and let you know.
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Old 4th August 2009
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great job and a great mod. very well written and pic documented.
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Old 4th August 2009
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Quote:
Originally Posted by TechRep View Post
I can't say for sure without taking a close look at the 03 mounting, but the process should be the same with a few different measurements and some tweaks to the mounts shown above.
It would be interesting to find out.
Maybe I can get a local 03 to look at and let you know.
Sounds good! I have an 03 that I would love to do that to. Great job!! In fact you can come to my house tonight after dinner and do it right?


Beautiful job!!

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That is a very good write up and a well done job.
Rep for that.
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