Custom fuel tank...

[Sharky]

Finally got so.e time in the garage...
Using a Suzuki 250 Across fuel.tank and custom made unit...ups capacity to 18-19 litres...

 

[tugla]

Holy sweet......where you moving all the junk from under the seat

 

[wildweasel_pt]

The only junk there is the COILS that if replaced with COPS will disappear...

 

[tugla]

The only junk there is the COILS that if replaced with COPS will disappear...

Batt and cables ??? Maybe I'm looking at his picture wrong, looks like tank runs up right behind the engine.....

 

[Sharky]

The fuel pump will be replaced with an in tank unit...I've got COPS and looking at the ignitec unit.
Mates are experimenting with modern high power small size batteries...

 

[wildweasel_pt]

Batt and cables ??? Maybe I'm looking at his picture wrong, looks like tank runs up right behind the engine.....

Yeah you got it right i wasn't looking properly...

 

[Sharky]

The new tank sits behind the frame rails leaving a nice gap for rear headers and an air gap between tank and hot bits....
Originally I was going to morph across and max tanks together but decided it was easier to use the across one and custom build the under seat part.
Started with plywood mock up to get rough shape and then made cardboard one.
This was lined with fibreglass resin as a quick sealer to allow me to fill it with water to get capacity.
Stock max is 15 litres...my cardboard one did away with the battery cutout and came out at 15 liters as well...plus the 4 3/4 in the across unit...sweet......

 

[Sharky]

Started the steel one today....1.2mm cold rolled.
Had a go at bending sheet....just one weld instead of using 5 separate pieces...worked a treat.

 

[Sharky]

Decided to trim the tank today...lowered seat height with minimal loss of capacity.

 

[Miles Long]

Groovy work so far, Mr. Sharky.
Looking forward to seeing the finished product. You will find that filling your bike from the tailend to be soooooo much more convenient than popping that middle section.....I know I did!
Our capacities are the same when I use my "street" under-the-seat auxiliary tank.....19 liters.
When I use my touring tank - without the seat - capacity goes up to 22 liters.
Cheers, Mate !

 

[satariel666]

Im in the process of designing the custom tank as well.
Still need some work but hopefuly be done this summer.

 

[Sharky]

I was just ready to get my tank to the welder when an old friend re-appeared and offered to make it out of aluminium.....for free !!!...well..I buy the bourbon and we both drink it lol
Here's a progress pick.

 

[one2dmax]

Nice weld work

 

[88vmx12]

I have one question.... I am guessing the fill is now moving to under the back seat?

G

 

[Sharky]

It's actually going to be behind the passenger seat.
Im going to use a harley pop up cap that sits in a Z650 tailpiece. I have a steel tank insert from Drag Specialities that we will fit into an Ali tube welded onto tank unit.
Tank has been designed so it will come straight out backwards with rear wheel removed. After all...how often does the fuel tank get taken out ?
I have an Ali deck plate unit coming that is basically like a 6" opening, screw in filler cap that will be under the seat as an inspection panel.

 

[88vmx12]

It's actually going to be behind the passenger seat.
Im going to use a harley pop up cap that sits in a Z650 tailpiece. I have a steel tank insert from Drag Specialities that we will fit into an Ali tube welded onto tank unit.
Tank has been designed so it will come straight out backwards with rear wheel removed. After all...how often does the fuel tank get taken out ?
I have an Ali deck plate unit coming that is basically like a 6" opening, screw in filler cap that will be under the seat as an inspection panel.

Very nice sounds very well thought out! unk: G

 

[Sharky]

Got the tank back today. ...all welded up inc baffles inside to prevent the fuel slopping from side to side.
I'll make up the mounting plates for pump, fuel outlet etc and fit steel thread inserts from the start. ..much easier than repairing a stripped thread in ali further down the track.

 

[PATMAX]

I could only imagine what an aftermarket supplier would charge for such a creation. My guess based on other extra capacity Vmax tanks would be north of $2.000 USD for someone to make money off such a piece. Truly one of a kind. Too bad you won't be able to fit a Maxgasser seat so your ass could keep pace with your new found range!
Well Sharky! Nice design and fab work.

 

[SpecOps13]

Wow, is that Awesome work. Amazing.....

 

[satariel666]

Like it too!