Let's make a gas tank!

General Composites Discussions Composites Talk
#1

Ok, so I am up for a challenge and want to fabricate a gas tank. I will update this OP with the latest pictures and post questions I have as the fabrication progresses. I am fine at this stage, but I am sure I will have some questions soon.

Disclaimer: I have never made a fuel tank before, so this will be improvised as I go.

I am ramping up the fabrication to full speed with the temperatures warm enough to play with fiberglass/carbon fiber now.

One thing really lacking on these bikes is range – the ability to go for more than a couple hundred miles on the road. I am hoping to make a tank with the capacity of an additional 4-5 gallons is the goal.

You will have to use your imagination, but I would like your thoughts on this. I will figure out these things as I go.
[ul]
[li]The OEM 449/511 seat will fit with minor modifications to the seat.
[/li][li]The OEM 510 plastics will be molded into the gas tank and part of the tank itself
[/li][li]The tank will be made from carbon fiber
[/li][li]The tank is not fitted perfectly and still needs minor tweaks
[/li][li]This is a rough idea of how it will look
[/li][/ul]

#2

I can’t tell what it is your doing in those pictures? Maybe because I’m not familar with the bike in it’s original form.

#3

The 2012 Husqvarna SMR511 has its gas tank in the subframe. I am adding another gas tank to the front of the bike (in the traditional gas tank placement) in addition to the one in the rear. It will be a feeder tank to the OEM tank that contain the fuel pump.

I cut out the middle of the 2010 SMR510 tank, molded the frame to match the 511 and them put the two pieces together, filled with foam, started shaping and laying glass to build the plug.

After this, I need to figure out the best way to build the mold and then a strategy for bonding the new pieces together for a solid seal.

#4

This thread is the inspiration to my project.

http://www.bayarearidersforum.com/forums/showthread.php?t=145975

#5

I can see where your going with this… Ive made a few bike tanks before…

If I were you Id seriously think about filling those side scallops to make the moulding easier - itll also give you a few extra ml’s.
Youll need to fiberglass finish the foam filled areas. Personally I would have moulded the inside of the fairings and used them as very good "roughs"for the plug. youll need to finish the plug to 800grit highbuild anyway before you can PVA release it anyway…

Once youve got to here well continue…

Have you thought how you’ll get the fuel out - gravity feed, pulse pump, elec, etc? Also where the outlet will be???

#6

you will need a polysulfide liner to prevent the ethanol from destroying the resin

#7

I have to fill in the sides now that I have the glass laid. The whole thing is glassed up and ready for sanding, filling…repeat until ready for primer. I have Duratec high-build primer ready to go. I will post when I am at this step ready to make the mold.

The Husky 511 has a main tank and a separate “EFI” tank. The main tank gravity feeds into the EFI tank. I plan to “T” off this connection and gravity feed from two tanks.

I knew about this, but this answers several of the questions I have. Thanks! Any good source for this in decently low quantities?

#8

I believe that I contacted PPG and they had some. Shoot them a message. Let me know what you come up with.

You can also try here, although I never contacted them, might be worth shooting them a line and seeing what they say. http://www.masterbond.com/properties/fuel-resistant-adhesives-sealants-coatings

#9

Don’t think any epoxy or resin will be fuel safe/resistant… 20_RC_51 is right… the correct polysulfide coating may work… make sure its methanol resistant!!

I know for sure Novalac epoxy coating #636 is methanol fuel resistant.

Coat the inside of your tank after it’s made.

#10

Fastrr, which one is that do you have the link? Have you used this product?

#11

I’ve noticed that resistance to ethanol containing fuel is a hot topic in this forum.
Therefore I’d like to share this information, which I came across a few weeks ago, when I was browsing the internet:
MasterBond has an epoxy which they claim is resistant to socalled gasohols, ethanol containig fuels. The product name is EP41S-1, the link for the product description is: http://www.masterbond.com/tds/ep41s-1
I have’nt seen the TDS but from the product description I can conclude, that the product should be perfect for the application in a gas tank, either as a coating or as an adhesive.

#12

Nice project you’ve got going on here… interested to see your progress!

That build thread for the SV carbon tank by tygaboy is great isn’t it? I’m sure that’s served to inspire a lot of people!

Just wondering what people here think about the method of using POR-15 to coat the inside of a fuel tank?

#13

Good Quality Vynal esther resin and terephthalic resins are fuel/ethanol resistant (both liquid and vapor to a certain temperature). methanol - id have to consult the tech data sheet…

#14

There are a lot of reports of marine guys having fuel tank deterioration with ve resins.