SV Carbon Tank project for Zoran

[tygaboy]

You wax the part just like you were waxing your bike/car. Wax on, Wax off. I usually apply at least two coats of wax. Be sure to completely buff off the wax between coats.

Once the part is waxed, it's time to apply the PVA which is a 'mold release'. It's a liquid that you can apply with a cloth or spray on. I just use a clean paper shop towel (those blue ones you can get at Kragen or OSH, etc.) and rub on a layer.

You need to move quickly so that you don't rub it once it starts to set up as that will spoil the surface you are trying to create. Essentially, the PVA dries to a very thin layer (you can't even tell it's there) that prevents the composite from actually touching the part - making it easier to remove the part from the mold. Hence 'mold release'.

 

[tygaboy]

Note the oh-so-high-tech Honey Bear PVA dispenser...gotta have a little comic relief every now and then...

 

[tygaboy]

Once the underside is set to go, I protect the top of the tank with a big trash bag.

Not pictured is all the fiberglass that's cut and ready to apply.

 

[tygaboy]

I use a pretty light weight glass for the first few layers at it drapes better and is easier to work into the tighter corners. Then I finish it off with layers of heavier glass to provide a bit of rigidity.

Occasionally, I'll even glass in a piece of metal or other stiffener, if needed. As I said earlier in this thread, there really are no rules - I use what makes sense to me.

I'm using the West Systems epoxies. I can get away with the 'fast' hardner for these simple layups.

And here's the end result: The underside splash mold all layed up and curing. I'll probably leave it in here for a couple days, especially because it's a bit cold in the garage.

Time invested so far, including all the cutting, cleaning, preping and layup = about 4.5 hours.

 

[I <3 Twins]

Way cool.

 

[MotoLiam]

Bitchin!

 

[FrigginChi]

when i used to work on custom car audio installs we used either speaker box carpet or cotton fabric<t-shirt like material> for splash mold material, since it doesn't need the strength of fibreglass, and because its cheaper..easier to sand..and most importantly it doesn't make you itch

 

[tygaboy]

when i used to work on custom car audio installs we used either speaker box carpet or cotton fabric<t-shirt like material> for splash mold material, since it doesn't need the strength of fibreglass, and because its cheaper..easier to sand..and most importantly it doesn't make you itch

Interesting, thanks for the info and idea - I may try that on a future project.

Hey, that gives me an idea - maybe I should use material as the outer layer (or part of the outer layer) of the final production part.

Hey, Zoran, how about a carbon tank with knee cutouts made from my old plaid flannel pajamas?

 

[TWF]

if your pajamas is yellow it is go

 

[drizz]

Looks great so far. You make it damn tempting to order some stuff and get cracking!

 

[tygaboy]

Ah, sweet progress. Popping a part out of a mold is one of the most rewarding events in life - particularly when it pops right out and, result-wise, is right on target. In other words, so far, so good.
Now on to the splitter plate and the top mold. Wish me luck!

 

[tygaboy]

And this underside mold would be suitable if I were to make a non race tank, too...

You can't see it in the pics but there are little dimples in the mold right where the petcock needs to mount - just like I wanted. I purposley 'dented' the tape when covering up the petcock mounting location so the location would be build into the mold. These marks will ensure there are no clearance issues with anything when we go to mount the final part.

Here's a shot of the other angle:

 

[paroxysm]

That is so pimp daddy bad ass. How much for a 636 tank

 

[big pete]

Great write up Chris . Keep us posted on every step...I'm interested in making a tank for my next bike

 

[firstbuell]

this really is the coolest thread

if the price is reasonable, I'd buy 1 of yer tanks for the '05 SV trak bike project.

I'm even ready to attempt building 1 up alongside you [& others?] - might you be hosting an SV CF tank party soon?

Zoran's been so generous, offering his invaluable guidance, and now it appears he's inspiring you as well....

 

[jonb]

I need a new tank for my 05 after my 'accident' this summer past. C'mon, Zoran will vouce for me. I need a CF tank for this sv I am building up...

Please

 

[TWF]

I need a new tank for my 05 after my 'accident' this summer past. C'mon, Zoran will vouce for me. I need a CF tank for this sv I am building up...

Please

it would be hard to make one for you.tank would need cut outs for car doors

 

[drizz]

Don't over-extend this guy. I have an interest in his possible next project

We're all on the edge of our seats, Chris

 

[HellFyre]

Ok, a raise of hands, how many would like a first-gen SV CF race tank?

tygaboy, just take some time off work and start popping these things out.

 

[drizz]

Ok, a raise of hands, how many would like a first-gen SV CF race tank?

tygaboy, just take some time off work and start popping these things out.

I'm hoping to learn from the master after he finishes his Zoran tank. After I do, I'm sure I'll want ot practice, so I may be able to accomodate. We'll see. I'm excited to give it a shot as a new hobby.