I'd like a little more explanation on how to accomplish this. Like how do you seal off both end of the tank? And how do you inject enough air at high pressure to expand the tank? I'd think this process could change the shape enough to throw the alignment of the shrowd bolts off as well as ruin the seal on the fuel petcock.
He sent me a PM. He takes the tank off the bike and fills it with boiling water. he did not say but I assume the petcock is closed. He said to five it a few minutes for the plastic to warm up and then use a very low pressure in the gas cap vent tube. He said start with zero and slowly go up to a max of maybe 15-20 psi. He said it will take several tries to get the tank to expand and I would need to drain cool water and re-fill with hot.
I do not want to go to a big tank unless I HAVE to. If I do, I think I will try this method first but I will do it on the bike with the shrouds attached. Little more work to drain water but less chance of deformity....I think. Additionally, it might be possible to expand just the lower portion of the tank if I dont fill it all the way up with hot water.
If I try it I will post results.