SV Carbon Tank project for Zoran

[tygaboy]

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...

If you read the thread, you'll see I mention that I use a pair of metal shears to do a rough trim and then use the Dremel with a sanding wheel to finish. I also use sandpaper of various grit, depending on the specific application. I also use a small air powered body saw for things like cutting out the gas cap opening. Look back at that pic and you'll see the part I cut out.
Both the air saw and the sanding wheel go through glass and carbon - even the Kevlar - no problem.

 

[tygaboy]

Time to mount the mount!
Scuff up the bonding surface, drill the initial fitting holes. These holes are probably undersized as we may want to use the original rubber mounts, in which case we'll enlarge the holes to take the stock doughnut bushings. This way, we have the option should we go another way.
I trial fit it to determine the centerline, check clearance, etc. This is my Gen 1 SV - Mmmm black powder coated frame, GSX-R 1000 front end...

 

[tygaboy]

Scuff the bonding area on the tank underside - after marking the location with Mr. Sharpie. Mix the epoxy, add filler and apply to both parts. Again, better too much than not enough! We'll simply wipe off the excess that squeezes out...

 

[tygaboy]

Fit the mount, press it into place and clamp it into final location. Excess epoxy/filler flows out ensuring we have a nice layer of goo between these parts.
Poifect!
You have to be a bit careful since the clamping surfaces are not parallel. This causes the Vice Grip to try and move the mount around as it locks. We're using pretty little clamping pressure. Enough to hold the part and force the excess epoxy/filler out, but not so much that we risk crunching the tank or anything like that.

 

[tygaboy]

Carefully wipe off the excess and gently wipe the entire tank down with Acetone to be sure no epoxy fingerprints or stray drops of epoxy found their way to somewhere they shouldn't be.
I should have taped off the parts of the tank that we wanted to protect but this was a simple proceedure so I risked it. So long as we give it a good inspection and clean up before the epoxy sets up, we're fine.
Then just let it cure and...
Shazam! - one front mount - mounted!
I may come back and add a few layers of carbon to sandwich the mount to the tank...let's see how I feel about that in a bit.
We are officially one rear mount bonding away from this project being done.

Home stretch...keep your form...relax...almost there...

 

[h2v7]

how much does it weigh?

 

[Bad Moon]

Originally posted by tygaboy
"... This is my Gen 1 SV - Mmmm black powder coated frame, GSX-R 1000 front end... "

What bodywork is that on the SV?
Can you show some pics of the other projects we keep getting glimpses of in the background?

Again, thanks for this thread.

 

[Zierra]

@ Chris: I have a little request for you...

Can you, by any chance, post pictures of the inside of the stock SV tank? It seems that you already cannibalized one to get the petcock mounting hole and the front mounting plate.

The reason I'm asking is that there might be some copycats out there (myself included) who are interested in making the 'anti slush' baffles inside the tank.

So pretty please?

 

[tygaboy]

@ Chris: I have a little request for you...

Can you, by any chance, post pictures of the inside of the stock SV tank? It seems that you already cannibalized one to get the petcock mounting hole and the front mounting plate.

The reason I'm asking is that there might be some copycats out there (myself included) who are interested in making the 'anti slush' baffles inside the tank.

So pretty please?

I cannibalized the stock tank(s) long ago and tossed out the 'left overs' so I can't do much for you. But it's pretty simple to imagine what the inside looks like. It's the exact same as the outside with the exception of the fact that there are (for CA tanks) two copper lines that run to the back of the tank - one for the vent and one for the gas cap overflow. Non-CA tanks, like the yellow one I started with for this project, have only the overflow as the gas cap handles the venting. Sorry I can't be more help.

 

[tygaboy]

Originally posted by tygaboy
"... This is my Gen 1 SV - Mmmm black powder coated frame, GSX-R 1000 front end... "

What bodywork is that on the SV?
Can you show some pics of the other projects we keep getting glimpses of in the background?

Again, thanks for this thread.

Glad you're enjoying all this. My SV bodywork is some stuff I'm working on. Some pics can be seen here:
http://www.bayarearidersforum.com/forums/showthread.php?s=&threadid=144643

 

[tygaboy]

Tank weight is...

I weighed the tank... drum roll please....
Stock = 12.8 lbs.
Carbon....here it comes....

4.85 lbs!

A 62% reduction in weight. Up high on the bike, too. This will be noticeable.

And as I've said, this tank could be made lighter. I think if I were to do it again, I could safely get it close to 4 lbs.
I'm pleased with this result. You should be, too.

 

[TWF]

Can you, by any chance, post pictures of the inside of the stock SV tank?

you can use foam for inside of tank.
here is pic inside.

 

[TWF]

Re: Tank weight is...

I weighed the tank... drum roll please....
Stock = 12.8 lbs.
Carbon....here it comes....

4.85 lbs!

A 62% reduction in weight. Up high on the bike, too. This will be noticeable.

that just means I can stop diet

 

[Killroy1999]

Re: Tank weight is...

I weighed the tank... drum roll please....
Stock = 12.8 lbs.
Carbon....here it comes....

4.85 lbs!

A 62% reduction in weight. Up high on the bike, too. This will be noticeable.

And as I've said, this tank could be made lighter. I think if I were to do it again, I could safely get it close to 4 lbs.
I'm pleased with this result. You should be, too.

Congrats! Carbon is not bling. It is a very high specific strength material used to lower weight. It the weight is not lower, there is no reason for the expensive material.

So, are you going to crash test you tank for safety?

 

[Bad Moon]

Glad you're enjoying all this. My SV bodywork is some stuff I'm working on. Some pics can be seen here:
http://www.bayarearidersforum.com/forums/showthread.php?s=&threadid=144643

Thanks.

On the SV bodywork, did you start with some existing bodywork and cut and shape it the way you wanted?

If you started from scratch how did you go about making the initial shape?

I would love to do a project like this but I don't know where I would find the time. I already have projects that aren't getting done. Please keep documenting your projects like you have been doing as I am really enjoying reading about them. It saves me a lot of time and money and keeps me from getting itchy by just reading about what you're doing.

 

[tygaboy]

The final fab is upon us! The rear mount.
In case I didn't mention it earlier, I got home from the 'trial' fitment at Sears and took a closer look at the rear mount...something's not right...
So I decided to hold off making it until I could fit the tank on Zoran's bike.
Well, yesterday Zoran was kind enough to swing by my place with his bike! I had asked him to help me with the wiring harness on my SV project so it seemed a win-win all around.
In any case, it turns out my suspisions were correct so I ended up starting the rear mount over again.
I've had great success using sheet aluminum (available at your local OSH, Home Depot, etc) as simple molds. For things like this rear mount, which is just a tab with a bend in it, it works really well.
Just clip out an appropriate size and mock up the needed shape. Then hot glue it to the trusty mold stand...

 

[tygaboy]

At this point, I'm assuming you've all seen enough to know how I lay up the composites so I won't go into all that.
Here's the part, rough trimmed and ready to be bonded to the tank. Had to clearance it a bit for the vent tube...
I'm leaving plenty of size in the part to maximize the bonding area as well as provide flexibility for final fitting and location of the mounting holes. Better safe than sorry.

 

[tygaboy]

"Lather, rise, repeat" applys to our tank project, too.
I'm sure you're all starting to see there are really only a few basic skill to all this. These next few steps are the same ol' "rough up the bonding surfaces, wipe with Acetone, mix the epoxy, add filler, goo up the bonding surfaces..."

 

[tygaboy]

Nothing like a pot of epoxy/filler first thing on a Sunday morning!
Apply to both surfaces...

 

[tygaboy]

...then set the rear mount in place. Check to be sure the filler is oozing out all around. Well, no problem on that count, huh?
(I just noticed this pic shows my very cool SV project bike watching from the other side of the shop. It's calling "Work on me, work on me!")
And yes, that is a large pig above the clock...don't ask.