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Drilling a tank for a horn unit

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the tinker

Cruisin' on my Bluebird
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Sometimes we have a tank that never had a horn unit ....and we want one.
I want to put this Murray [ third from left] back on the road. Tank is a little rusty as you can see and it never had a horn unit in it. First off I want to get rid of the surface rust in the paint so I will give it a bath in Oxalic Acid for about 20 min. These wallpaper trays are great for soaking tanks and forks and are inexpensive.to purchase.
After the rust is removed I will drill the holes needed to install the horn.

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Next I want to locate locate the holes to fasten an original Delta horn in place. For that you will have to have
someone allow you to place a hunk of tape on their tank to exactly locate the holes needed to attach your horn.
just happen to have this spare tank handy.......:)
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Place a strip of tape aligned on the edge of your tank . Start the tape at the front corner of your tank .
exactly mark the center of the holes ......:(
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Peel the tape off and place on the other tank in the exact position.
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With a "spring loaded" center punch [ available at Harbor Freight for about 4 bucks] mark your holes.
DO Not use your regular punch with a hammer as YOU WILL dent the tank.:mad:

Select the smallest drill bit required for the mounting holes and drill ALL your holes.
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Using the smaller hole for a guide next use the larger bit you have selected for the horn button hole.
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Install your horn unit and your tank now has a horn.:) Done!
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For the horns that have the Large horn Button typically on the side of the tank I do it the same way only I hesitate to use that large of a bit on thin sheet metal as it may catch and tear the tank wall.:mad:
I "fine tune" the hole to the exact size using the abrasive hole saw pictured on the far right. [ cheap & available at Harbor Freight] Also a step drill bit can be used but these are not cheap, especially if you may only use it once.$$$$
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Pictured at left above is the typical hole saws and spade bits. These bits work well for drilling through the sheet metal on a metal door but should not be used on your precious tank. While drilling through the un backed metal of your tank these bits will "walk" and you will really,:( really:( hate yourself.:mad::mad::mad:
 
Great tech post. A good way to open up a hole to slightly larger is with the dremel diamond 1/4" bit. It cuts most anything like butter. Worth the money. I have used it on many projects.
 
Small holes drilled no bigger then 3/16 or less and a hand turned tapered reamer I get me from harbor freight works super in sheet metal making th exact hole diameter you want.
 
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