'97 ProGlide

[Easyrider]

Once you remove the old paint savers, standard Harley caps will fit. New paint savers will take a reduced diameter cap and use the spanner listed on Bigdogpartsking site. Small punch and deadblow hammer and a rubber strap wrench may loosen the OG paint saver? Most were installed using JB Weld. Good luck. Keep us posted.

Edit: Matt Moore is the current owner of BigDog motorcycles. Derrick and Donna run HDM(Bigdogpartsking) and Curtis is owner/operator of WSW(WildSteedWorx)

Fixed a number of the issues I asked about previously. The biggest pressing issue for me is removing the fuel tank filler insert and replacing it with something OEM or high quality [bolt in] aftermarket.

The caps fit so loosely that air gets in there and 1/2 gallon to a gallon of gasoline will evaporate in the tank over a several month period. I'd really like to resolve this.

I can't get the insert to budge and it may need a special tool. I don't want to get too gorilla with it just in case it's welded in there so tightly that trying to remove it will mangle it. The bike is obviously ride-able and I don't want to disturb that.

The outer ring paintsavers are off so it's the insert into the tank that doesn't want to come out.
I also want to have replacement/upgrade parts in hand when I start the project (again). I did e-mail BD parts king.

 

[HMAN]

Pics of what you have left will help. The paint savers may have been put in with something like JB WELD. Heat may help but make sure the tank has been completly flushed so zero fumes. Heat gun and some channel lock pliers may move it? Good luck.

 

[Easyrider]

Pics were posted earlier in this thread. These inserts were likely installed with a special tool. How strong would a JB WELD adhesive be? I've tried a few tools and exerted a fair amount of strength and it wouldn't budge. As I noted, I don't want to mangle the insert if it's not going to come out willingly. If going full gorilla on it will DEFINITELY get it out of there then I'm willing to go for it (if I have an insert in hand to replace it with). My sensibilities say no to high heat on a gas tank, flushed or not. I'd like to do this R&R as painlessly as possible.

 

[Snuffy]

Before applying heat or welding on a tank fill it with water.