Suzuki GT250 -73 Build pt2: Building an Aluminum Motorcycle Gas Tank from Scratch

Fabricating an Aluminum Motorcycle Gas Tank from Scratch for a Classic Racing Suzuki Super Six T20 / T250 / GT250 / Hustler / TR250

This is the first aluminum fuel tank I’ve ever built from scratch. My inspiration came from Mr. Pete Williams’s YouTube video, "How I Make an Aluminum Motorcycle Petrol Tank (Gas Tank) & Other Alloy Metalwork." I really like his method because it minimizes the need for panel beating, making the process much more approachable.

Since I didn’t have a template for the tank, I designed the tank shape and cutting template using FreeCAD. If you’re curious about how I did that, check out the video from the link below.

I used a 1.5 mm EN AW-1050A aluminum sheet because that’s what was easily available locally here in northern Finland. For filler rods, I already had 1.6 mm ER4043, so I used those. While there’s a slight color difference visible after 220-grit sanding, it’s unnoticeable once polished.

Lacking the equipment (and maybe the skills!) for aluminum oxy-acetylene welding, I relied on my cheap Chinese TIG welder to see how it would turn out.

The cap socket and tap flange were machined using my DIY Arduino GRBL-based milling machine.

This tank is for a vintage racing motorcycle, so perfection wasn’t my priority—especially since it might not survive the first corner on the track! That said, I’m really happy with how it turned out.

For the finish, I went with a semi-gloss look, leaving it intentionally a bit rough. This saved time (since there’s still plenty of work left on the bike!) and gave it a raw, handmade aesthetic that I really like.

Thanks for watching, and stay tuned for more updates on this classic racing bike build and racing!

Mr. Pete Williams’s Channel
‪@doubleenginedtriumph‬

Mr. Pete Williams’s video, "How I Make an Aluminium Motorcycle Petrol Tank (Gas Tank) & Other Alloy Metalwork."
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Design gas tank and template with FreeCAD
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