SV Carbon Tank project for Zoran

I just found this thread and what amazing work you've done!

When I was younger and still living in So. Cal. I used to help a friend build kayaks, and I'm now kind of inspired to start playing with this stuff again. Thanks for all the time and effort to share this with the community!

-Brent

Well, I got back from a nice dinner out with my wife and friends and, wonder of wonders, ended up back in the shop. Started thinking about an additional method of securing the cap. Turns out I want those cap bolts after all. I made up two little carbon strips that have a slight bend to them. By using the gas cap bolts, we end up with a couple 'locking wings' that bolt to the gas cap and extend out into the tank and pull the cap down even more securely. Then, I added a couple layers of carbon that will add even more holding power. In all, this cap assembly shouldn't be going anywhere.

And since I had all the supplies out and spare epoxy just sitting there, I figured we might as well finish up the vent system.
We bond the vent cap to the tank top, just behind the gas cap - that's the highest point in the tank and other than splashing, gas doesn't get up there. I won't go into the design of the vent other than to say it works in the stock tank and it'll work here, too.
Then, having previously bent the copper tube so it'll touch the side of the tank and route out the back, we bond the tube to the side and strengthen it with a few layers of carbon. Then, just goo up around the tube where it exits the rear of the tank. You've already realized I drilled a suitable hole there earlier...

One word of caution: CHECK THAT THE VENT SYSTEM DOES NOT INTERFERE WITH THE FITMENT OF THE BOTTOM OF THE TANK.

One guess why I mention this in uppercase.

Yup, I had the line all bent and the entire system all goo'd up in place to cure and I thought, "Hmmm, I better check to see that everthing clears..."
Good thing I did - 'cuz it didn't!
No biggie since nothing had even started to set up. But I had to pull it all out, bend the copper into a totally different shape and redo the fitting of everything.
Like you've always heard: Measure twice, goo once.
But all's well now. And there is only one more pic to come of the inside of the tank - when I apply the sealer. Then it's time to bond top to bottom. Should have that all done tomorrow.

I gotta get a life - in the shop until about 11:30 last night, back out there at 6:30 this morning. Good thing this is almost done!
As mentioned, we want to ensure we have no issues with leaks. Surprising as it sounds, my first SV/MV tank passed gas , er, weeped gas through its side. I couldn't believe it. Leaking through five layers of cured composites? WTF? It had to be something I did or didn't do. That's when I became friends with tank sealers. Saved my bacon on that tank, let me tell you.
In any case, I've greatly improved my layup skills and I'm confident this tank doesn't really need it, but I'm a fan of 'let's be sure, shall we?' so on goes a layer of POR-15 gas tank sealer. Just paint it on with a cheapy disposable brush, same as we use for the epoxy work.
BTW, why am I confident this wouldn't have leaked? I filled it with water when it first came out of the mold and it passed the 'doesn't leak' test!
One sealed tank ready to be closed up and put into service.

And I couldn't resist a shot of the finished cap. Mmm, mmm, mmm. Tasty!
Now let's bond top and bottom...

The tank sealer is all but set up so we're OK to start working with the tank without having to worry about that stuff getting anywhere we don't want it.
First, cover the outside of the tank to prevent any stray epoxy from getting on it. Some handy packing paper and magic blue tape and that's that. You can also see how the vent tube exits the rear of the tank. A bit of forethought and we end up with a design that lets us mount the bottom without having to worry about the vent exit getting in the way.

To prep the bonding area, scuff it with some 80 grit sand paper then clean it with Acetone. I preped both bonding surfaces this way.

Mix up the epoxy and season with filler to taste. Apply liberally to both surfaces - we'll be cleaning up the excess and we are far better off with too much than not enough. Nothing worse that having to play 'on and off, and back on again' at this stage of the game.

And now it's time for the big event! Place the bottom on the tank, figure out the clamping/pressure system and get it all happening before the epoxy starts to set up.
It's nearly impossible to figure how we'll need to clamp things until we get the filler into play. Why? That's when you can see where it oozes out 'naturally' and where we need to apply some pressure to get the bottom lip to conform to the top part's lip. Even though you see Vise-Grips in use, they are set to barely squeeze. The tank bottom edge is fairly flexible so it's less dramatic than it might look.
And full paint cans and 2x4's are your friends. Again, not too high tech, but it works just fine.

And here's what we're after - the epoxy squeezing evenly out from the seam. I've already wiped off the majority of the excess and I'll leave what you see here.
Once this is cured, it's all but finished!


Whew...I'm getting tired - how about you?

FUCKING AWESOME!!!

i would have expected the kitchen sink on top of all those cans !

Maybe this was already asked, but how much lighter is the carbon tank?

That is the point, right?

Killroy1999 said:

Maybe this was already asked, but how much lighter is the carbon tank?

That is the point, right?

Click to expand...

Yep, but no weight comparo until this is done, has the mounts, etc. so we can do an apples-to-apples to see the total benefit. If I was to make another one of these, I'm sure I could make it lighter than this one - I know I would modify the patterns - but this one should yield significant weight benefits. We'll know for sure in a few days.

Ladies and gentlemen - never before seen by human eyes - may I present Zoran's Carbon SV race tank!
OK, OK, we still need to add the mounts, but come on, I'm EXCITED!

Another view - here you can see we've trimmed the vent tube to production length. It's feeling pretty light, too!

Down to the final couple steps...
Let's make the front mount. Remove the mount blank from the mold and give it a quick rough trim with the metal shears. Then, I use a piece I cut from a junk SV tank as a template to draw out the final shape.
Hard to tell here but the mount blank is set up such that it will bond to the underside of the carbon tank, wrap underneath the front edge and then the two 'ears' will serve as the mounting points, just like the stock one.

And here's our custom shop vac hose mount for use when shaping with the Dremel.
Haven't I said it enough already? ALWAYS WEAR YOUR RESPIRATOR! The vac takes care of virtually all the dust but don't risk it, please!
And the remote extension is easier to use than wielding the Dremel motor. Keeps the carbon dust away from the motor, too.

One carbon front mount, ready for bonding and final mounting hole drilling.
Well, that's it for this weekend. I hope to finish the tank this week.
But we made really great progress the past two days. Almost there...

But as we enter the home stretch, I've started thinking about a much bigger question:
What will I do once this project is done...?

Wait, I know! Oh, you Ducati fans are going to love this...

Awesome thread! Tons of knowledge and skill you have.

I got one question, what do you use to trim the carbon fiber after its hardened? I built a custom body for my bike out of fiberglass, and i had a hell of a time trimming shit. I ended up buying a little saw blade for my dremel (which I went through 2 already) and I was thinking there has to be a better way...

Oh, and if you wanna see the preliminary test fitting of my body, you can at http://www.1000rr.net/vb/showthread.php?t=17285&page=1&pp=10