Net-Moto :: Community :: Racing :: :: Racing Videos Sponsor :: Contact
 Forums   Features   Trackdays   Moto Crash Incidents   Race Team   CMSP Training   Sponsors      Donate   Terms of Service 
BARF - Bay Area Riders Forum  Home   UserCP   Register   Calendar   Members   FAQ   Search  AMA

Go Back   BARF - Bay Area Riders Forum > Moto > Moto Photos & Videos


Reply
 
Thread Tools Display Modes
Old 12-09-2005, 06:09 PM   #1
tygaboy
Veteran
 

Join Date: Jun 2004
Location: Petaluma
Motorcycles: The current project bike
Name:
SV Carbon Tank project for Zoran

Proving the old saying 'Ask and ye shall receive', Zoran saw the thread about my SV/MV project and the carbon tank I'd made. He also saw my reply to a question about how much it would cost for me to make a tank - to which I replied something like "I don't want to turn the hobby into a job and I prefer to make things like this for friends...'

Zoran's next post started out with "Well, my friend..."

Long story short, I've decided to build a carbon/kevlar tank for Zoran and his race SV. I thought you all might enjoy watching the start to finish process. I'll be posting as I move through the project and hopefully this will dispell some of the the black art and mystery around composites.

For those of you who've not seen the tank I made for my SV, (pic attached) I think you'll be surprised at what a hobbiest can achieve in the privacy of his or her garage. Perhaps after watching this project come together, some of you will be motivated to give it a try! I'm half tempted to host a 'come to Petaluma and learn how to make composites - maybe an exhaust hanger or something simple...anyone interested? I'd charge for cost of materials only...it'd be a hoot. Give me a holler if you want to know more.

So anyway, let's get going. I've not even started but let's look at the process I'm going to use. There are any number of ways to do this, which is half the fun - there are almost no rules...but here's what I like to do:

1. I'm going to start with a stock SV tank, fill in the gas cap area and modify the area around the seam that joins the top and underside stampings to make a more 'composite production-friendly' shape - more on this later in the project.

2. Once I have a shape I like, I'll make what's called a 'splash mold' (a non-production quality mold) of the top and the underside.

3. I'll use the splash molds to make fiberglass-only parts that will be bonded together to make what's essentially a fiberlass replica of the stock tank.

4. Zoran, an experienced crasher of SVs, has proven that the sides of the stock SV tank stick out too far and are very susceptible to damage - see attached pics of the fabulous donor tank he's provided me as the starting point... So, I'm going to modify the fiberglass replica and narrow it as a pre-emtive design modification to combat the literal impact that might occur when one combines gravity and asphalt.

Note: Carbon fiber won't dent, it'll crack and break and splinter and grind away to dust if you impact it (with enough force) or drag it across a rough surface. It's not impact resistant. That's what the Kevlar is for.

4. Once these mods are all done (lots of bondo, popsicle sticks, and hot glue!) I'll have a model of the final shape I want. This is called the 'plug'. And now it's time to sand, sand, sand to get the finish as close to perfect as possible.

5. Once the plug is finished, I use it to make the production molds. It will likely be a three piece mold: a two-part top is needed if there are any combined surface angles that would cause what's called 'mold lock'. Think of making a mold using a lightbulb - you couldn't get it out of the mold unless the mold could be split. So the top will utilize a 'splitter plate'. I'll need to make one in order to make the splash mold so you'll see one of those soon enough...

6. Finally, once I have the production mold, I can layup the parts and make the tank. Or should I say tanks!

7. I may decide to make these available to others, we'll see. Depends on demand, how labor intensive they turn out to be, etc.

Zoran will likely not be greeted by a large, lightweight Christmas gift but I'll work on it as time permits.

So, stay tuned and feel free to contact me with questions, comments, etc.

Chris Baker
chris.b.baker@kp.org

__________________
Chris

Last edited by tygaboy; 12-09-2005 at 06:16 PM..
tygaboy is offline   Reply With Quote
Old 12-09-2005, 06:11 PM   #2
tygaboy
Veteran
 

Join Date: Jun 2004
Location: Petaluma
Motorcycles: The current project bike
Name:
...and here's my SV custom tank. Well, the top part anyway - fresh out of the mold. It's even prettier in real life.

__________________
Chris

Last edited by tygaboy; 12-09-2005 at 06:17 PM..
tygaboy is offline   Reply With Quote
Old 12-09-2005, 06:15 PM   #3
GearSlammer
Veteran
 
GearSlammer's Avatar
 

Join Date: Dec 2004
Location: San Fran.
Motorcycles: 07 600rr
Name:
very good.
explain the kevlar part please.
also, how strong does this stuff end up being?
it would be nice to have a nice exhaust hanger.
GearSlammer is offline   Reply With Quote
Old 12-09-2005, 06:19 PM   #4
tygaboy
Veteran
 

Join Date: Jun 2004
Location: Petaluma
Motorcycles: The current project bike
Name:
Kevlar is designed to be impact resistant - it's the stuff in bullet-proof vests. That's why you always see composite tank manufacturers mentioning that they use kevlar. I wouldn't get near a bike with a carbon-only tank...
__________________
Chris
tygaboy is offline   Reply With Quote
Old 12-09-2005, 06:37 PM   #5
little_twin
Veteran
 
little_twin's Avatar
 

Join Date: Nov 2005
Location: Rohnert Park
Motorcycles: YZ250, YZ250f, GSXR-750, DL-650, TE449
Name:
I'd definately come to petaluma to make an exhaust hanger for my sv.
little_twin is offline   Reply With Quote
Old 12-09-2005, 06:51 PM   #6
drizz
it's monkey madness!
 
drizz's Avatar
 
Founding Member
Contributor

Join Date: Aug 2002
Location: prescott, az
Motorcycles: 2 lil, 2 big
Name: Dave
Quote:
Originally posted by MackeyStingray
sweet. already looks amazingnow this i'm definitely interested in
+1 Sounds like someone's hosting a party
__________________
::: Drizz ::: aka "The Dave" :::
2007 Husky SM450R | 1976 Harley Sportster 1000 | 2002 Monkey (big) | 1998 Monkey (little) | 2003 RM125 (for sale) | Spectre 210
LeoVince | Santa Clara Cycle Accessories | Evolution Suspension | Planet Minis | Dropzone.com
drizz is offline   Reply With Quote
Old 12-09-2005, 07:05 PM   #7
TWF
training hard
 
TWF's Avatar
 
1% Contributor

Join Date: Feb 2004
Location: desert
Motorcycles: sv's
Name:
Re: SV Carbon Tank project for Zoran

Quote:
Originally posted by tygaboy

4. Zoran, an experienced crasher of SVs,
sometime it is worth crashing
TWF is offline   Reply With Quote
Old 12-09-2005, 07:20 PM   #8
uhmeebuh
Ginger Ape
 
uhmeebuh's Avatar
 
Contributor

Join Date: Jul 2004
Location: where it's winter half the year
Motorcycles: are dangerous
Name: Brandon
Great idea! Thanks for sharing this info and the process.
uhmeebuh is offline   Reply With Quote
Old 12-09-2005, 07:43 PM   #9
eisenfaust
WHARRGARBL
 
eisenfaust's Avatar
 

Join Date: Oct 2005
Location: Berkeley
Motorcycles: SV650 Streetfighter
Name: Patrick
I'd like to come up and make an exhaust hanger.
__________________
So here we here we go, now its time to decide, because a true believer's always ready to die.
If it's true what they say, then it doesnt matter anyway, and if it's not then you just threw it away.
The beginning of the end starts right about now, but we're gonna make it through somehow.
So in the end if you've always believed, then you better give it all when you give it to me.
eisenfaust is offline   Reply With Quote
Old 12-09-2005, 08:26 PM   #10
eeeeek
Freelance Superhero
 
eeeeek's Avatar
 

Join Date: Mar 2003
Location: Loomis
Motorcycles: Various
Name: Vik
Cool idea on the arts and crafts day. I'm interested.
__________________
Vik
AFM 64
So I Bought an Air Force

Quote:
Originally Posted by Lunch Box View Post
In the end, I figure that it just doesn't make sense to get offended for others.
eeeeek is offline   Reply With Quote
Old 12-09-2005, 08:26 PM   #11
tygaboy
Veteran
 

Join Date: Jun 2004
Location: Petaluma
Motorcycles: The current project bike
Name:
Quote:
Originally posted by GearSlammer
also, how strong does this stuff end up being?
it would be nice to have a nice exhaust hanger.
"Strong" is a relative term. A gas tank doesn't need to be 'strong' per se. It needs to be 'tough' and 'not leak'. Composites are just an alternate material that might be used to fabricate a part.

But for stuff like exhaust hangers, it's plenty strong. I made a carbon hanger for my '03 SV track bike - it took me all of about 1/2 day and that included letting it cure enough to allow me to do final shaping. I let it post cure on the bike.

So any of you with 2nd Gen SVs, we already have a mold we can use...
__________________
Chris
tygaboy is offline   Reply With Quote
Old 12-09-2005, 09:03 PM   #12
afm199
Veteran
 
afm199's Avatar
 
Mod Alumni
Founding Member
Top Percent Poster
Contributor +++++++++ ++++++++++++++3%

Join Date: Sep 2002
Location: Oaklamd
Motorcycles: Yamasuzhonaki 1450
Name: Beelzebub
Back in the day in Britain, fiberglass tanks got banned because they were so poorly made and flimsy that they resulted in numerous fires. That's the one concern with composite/fiberglass tanks, you don't want to go down hard and have it dump five gallons of Nutec on your shiny new leathers next to a sparking titanium metal slider.
__________________
That's not true! The lie is actually the truth! I know. Lots of people know this.
afm199 is offline   Reply With Quote
Old 12-09-2005, 10:07 PM   #13
little_twin
Veteran
 
little_twin's Avatar
 

Join Date: Nov 2005
Location: Rohnert Park
Motorcycles: YZ250, YZ250f, GSXR-750, DL-650, TE449
Name:
I've got an 03. I'd like to come and at least see how the process works.
little_twin is offline   Reply With Quote
Old 12-10-2005, 11:19 AM   #14
jonb
Veteran
 
jonb's Avatar
 
Founding Member
Barf Racing Sponsor

Join Date: Mar 2002
Location: SF, CA
Motorcycles: 690SMC
Name: Jon B.
i want one :9~
jonb is offline   Reply With Quote
Old 12-10-2005, 11:25 AM   #15
MotoLiam
Lifelove:Forever
 
MotoLiam's Avatar
 
2006 Barfie
Moderator Alumni

Join Date: Jun 2003
Location: Living at Full Throttle
Motorcycles: are a driving force in my life. They keep bringing me back . . .
Name: Liam
Awesome thread idea Chris! I love it when people use their hands and brains to do something right! I can't wait to see the rest of this thread, and I wish I was around to come up to Petaluma and learn some things from you! Everyone, please take advantage of Chris' generous offer to teach you some things and perhaps plan a barf ride to head out there on a saturday or sunday. Who wouldn't want a custom exh. hanger (or some other small custom part) and be able to say, I made it myself!
__________________
www.PeterLenz.com - May you ride forever, my friend.
www.MotoLiam.com - The Kind-of-Complete Chronicles.
www.Motostrano.com - The Complete Store.
MotoLiam is offline   Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -8. The time now is 06:44 PM.


Powered by vBulletin® Version 3.8.7
Copyright ©2000 - 2018, vBulletin Solutions, Inc.