The search for a wide tunnel motorcycle gas tank ends with practical, fit-focused choices for custom builds. This guide highlights five tanks suited for Sportster, Harley, bobber, and chopper projects. Each option is evaluated for compatibility, capacity, and notable limitations to help riders select the right tank for long rides or show-quality builds. The top picks suit different riders: from classic Ironhead bobber builders to extended-range touring riders and DIY customizers seeking raw steel canvases.
| Product | Brand | Approx. Capacity | Best For |
|---|---|---|---|
| Wassell Frisco Mount Shallow Tunnel Tank | Skull | 2.3 gal | Custom builds needing two 1/4″ NPT petcocks |
| Wassell Mid Mount Dished Tank | Wassell | 2 gal | Classic Sportster/Bobber chassis |
| TOFR 4.2 Gal Tank | TOFR | 4.2 gal | Long-range Sportster XL models |
| 2.4 Gal Harley Ironhead Tank | Unknown | 2.4 gal | Ironhead Bobber and daily riding |
| SLMOTO 3.4 Gal Tank | SLMOTO | 3.4 gal | Honda Rebel 250 styling on motorcycle builds |
Wassell Frisco Mount Shallow Tunnel Gas Tank
Capacity is 2.3 gallons with overall dimensions of 14.5″ long, 9″ wide, and 7.5″ tall. This tank is designed for universal Frisco tunnel mounting and includes bungs for two 1/4″ NPT petcocks. Best for custom builds that require dual fuel outlets and a low-profile tank profile. The higher width helps stabilize fuel routing on wider frames. A potential limitation is the reliance on unaffixed tabs for mounting; alignment will need precise fitting during fabrication. Choose this if you need dual-petock capability without a deep tunnel.
Dished Wassell Mid Mount Tank With Tunnel
This 2-gallon tank is shaped for mid-mount placement and has a peanut style silhouette suited for Sportster and bobber builds. It features a dished design that aligns with classic lines while maintaining a practical capacity. Best for riders who want a traditional look with a compact fuel capacity and straightforward mounting. A note: ensure your frame supports the mid-mount geometry and that the tunnel depth accommodates the petcock fittings you plan to use.
TOFR 4.2 Gallon Gas Tank With Cap
Designed for 2007-2022 Harley Sportster XL 883/1200 models, this large-capacity tank expands range to reduce refueling frequency. It includes a tank cap and is intended for extended-ride enthusiasts. Best for riders prioritizing longer trips and fewer fuel stops. A caution: verify compatibility with your specific Sportster sub-model and ensure the wider tank clears any exhaust routing or seat subframes in your build.
2.4 Gal Harley Ironhead Style Tank
This universal tank is marketed for Harley Sportster Ironhead bobber builds from 1955–1978, with raw steel so users can paint or customize to taste. Its 2.4-gallon capacity is practical for daily riding and weekend cruising. Best for purists who want a bare-steel canvas and an authentic-era silhouette. Limitation: raw steel requires finishing work to protect against corrosion and to achieve a finished look in the final build. Consider this if you want a ready-to-customize base.
SLMOTO 3.4 Gallon Tank For Honda Rebel
Officially sized for Honda Rebel 250 (CMX250) models, this 3.4-gallon tank offers a larger capacity that appeals to riders seeking extended rides or a more aggressive tank presence on non-traditional builds. Best for experimental or cross-brand styling where a wider tunnel complements a bold design. Caution: ensure the tank’s mounting interface matches your bike’s frame, as it is a non-Harley-specific variant and may require custom brackets.
Buying Guide
What should you consider when choosing a wide tunnel gas tank?
- Capacity vs. weight: Higher capacity increases range but adds weight and potential center-of-gravity changes. Match capacity to your typical ride length and handling preferences.
- Mounting style: Frisco tunnel, mid-mount, and universal tabs affect compatibility. Confirm tunnel depth, tab placement, and mounting hardware with your frame.
- Petcock configuration: Tanks with two 1/4″ NPT bungs enable dual outlets or more flexible fuel routing. Plan your fuel lines and petcock type before purchase.
- Material and finish: Raw steel offers customization opportunities but requires finishing; painted or coated tanks resist corrosion and match your bike’s color scheme.
- Compatibility: Always cross-check model years and sub-models (e.g., Sportster XL, Ironhead) to avoid clearance issues with exhaust, fenders, or seat pans.
- Aesthetics: The peanut, curved, or dished shapes influence how the tank integrates with tank shrouds, handlebars, and line of sight on the build.
FAQ
- What is a wide tunnel gas tank best for?
– It suits custom builds requiring more interior capacity, dual petcocks, or a distinct silhouette in bobber and chopper projects. - How do I verify mounting compatibility?
– Check tunnel type (Frisco, mid-mount), mounting tab layout, and whether tabs are pre-drilled or require fabrication. - Can I paint a raw-steel tank myself?
– Yes. Raw steel offers a canvas for custom paint jobs, artwork, or polished finishes, but requires rust protection post-painting. - Is a larger tank always better?
– Not necessarily. Consider seat height, rider stance, and frame clearance to prevent interference with exhaust, side covers, or the rider’s leg movement. - What about reliability of petcocks?
– Tanks with two bungs provide flexibility but ensure appropriate flow rates and mounting for dependable fuel delivery on long rides.