I was considering making some molds off of my tank and building one out of fiberglass and/or carbon fiber. I have a little bit of rust in my tank and I know that most people do as well. Also after reading all the posts about lining the tank I think that at best it's a pain in the ass and at worst it's a carb clogging nightmare. So I was thinking about building one out of fiberglass with the outer layer from carbon fiber. Fiberglass can't rust and can handle gas so it should be a permanent solution.

I think a clean tank goes for around $100 or so  and I was wondering if people would be interested in buying one for around $150. I hope to have a simple petcock (maybe two, one with a tube sticking up a couple inches and another at the bottom for reserve) to eliminate the vacuum one that many have trouble with. And probably a simple non locking gas cap included. I don't think it would be worth it to just make one for myself but if 3 or 4 people wanted one (if mine turns out well) it would be worth it and I'll probably start working on it, so let me know.

Oh yeah, I have a "99 so it would probably fit 89-01 

Later 

Actually carbon fiber and fiberglass can't be trusted with gas alone...you'll still have to seal the inside.  The biggest issues you'll have are molding in bolt mounts for your gas cap, petcock and a line for the vent.  Then there's going to be heat/cold fatigue...both fiber and glass will deteriorate rather quickly.  Don't expect more than  10 year life from them.

I wouldn't suggest molding the stock tank.  Go get you some clay and slap on your tank and make it bigger.  That's going to be what sells the piece...if it holds more gallons...not carbon fiber or "rust proof".

I was planning on using epoxy resin with the fiberglass and carbon fiber. Plenty of boats have fiberglass gas tanks without a problem, and my dad's airplane has fiberglass tanks with no problem and it's 11 years old. I don't think that the heat and cold fatigue would be a factor either, The Ultraviolet would be a problem though, and the unpainted tanks would deteriorate over time. I'll try to find a clear coat that has some UV blockers to delay the process as much as possible.

If you look at older bikes with carbon fiber, some of them (except for the low mileage garage queens) have fading carbon fiber. Not too much you can do about it except paint over it, but that's the price you pay for bling  If you keep the bike covered, it takes a while before it deteriorates.

Hey Ducatinolan,

Cool idea!  If I had the cash, I would sign up.  A friend of mine just bought a Triumph Speed Triple with a plastic tank.  When I first heard he had a plastic tank, I thought it would look and feel cheap.  I was wrong--it looks great!  How difficult would it be to cast a plastic tank vs. fiberglass?

Chilly

Plastic molding isn't comparable.  It requires a source of rellets, a large oven, and lots of time.  Carbon composites are the way to go.

Doesn't carbon fiber shatter when hit in a small area?  Similar to most of the dents people have in their tanks?  I really like the idea, but it would suck if the bike went down and all of a sudden the gas tank shattered.

Maybe just overthinking ... I'd be interested .. especially if it was a touch bigger.

Good carbon fiber will need to have a substantial hit to shatter...as in something would have to hit it hard enough to collapse or puncture the stock tank.

But yeah, Nolan, I don't think people are going to invest in something like this if you make it a stock replacement.  Make it bigger and you'll get a lot of customers.

I think you need a bunch of special stuff to do plastic, Usually it's injection molded at high temps I think. It's a little out of the realm of the do it yourselfer Fiberglass isn't very high tech, you make a mold out of something and lay it up by hand, no high temp stuff required just a lot of work making the molds.

I have built a kayak using stich and glue plywood/fiberglass/epoxy and it turned out well, but I haven't molded stuff before. I was thinking this would be a fun first project to try and if it turns out well, I may be able to sell a few to recover the costs.

yea I was kicking arount this idea also, I beleive they make a special epoxy resin just for making gas tanks...

I'd be interested... but I have an '02.. so no fit.. =(

What's the difference in the '02 and newer tanks?  I'm sure that when casting a completely new tank it wouldn't be difficult to conjure up something that would fit both.

I was originally thinking that a stock shape and size replacement would have the most interest, but since it sounds like everyone wants more capacity, how do you guys want this done? taller, wider or just a little bigger everywhere? I only want to make one mold and I want the most interest possible.

Also how much bigger should it be? I could probally get another 1/2 gallon out of it without changing the look too much, but getting a gallon more in there would probally change the look considerably.

I think if you add an inch or two to the height it'll still blend okay and you'll get another gallon out of her.  But before you start casting you'll have to get 10lbs of clay or so to slap on top of your stocker (or whatever you're using as a plug) and blend the increased capacity in.

No one would buy it if it were a stock replacement.  Sourcing a another stock tank would be far cheaper.  You'll have to add trickery to make it sell.

At 150 it will sell if it was stock replacement too ... why ...
Lets see, people crash and crap out tanks, and of course the crap pockets crap out tanks at nearly that magic 10% mark, and agreed its not the end of the tank, but the srinath charges $50+ to coat the inside and prolly another 50+ for powdercoating the putside in solid primary colors ... so you'd prolly sell a dozen every year, more if you whored it out on flea bay ...
I would want all of the stock functionality though ... like locking cap and the petcock (yea 2 tubes sticking out is OK).
Cool.
Srinath.

the older bikes have a smaller tank . the newer ones are a bit bigger i know i'v sat on a 97 and then my 05

I was also wondering about the 02 and up tanks and if I could make something that fit both. I think it's mostly different where it joins up with the seat. Don't the newer bikes have a different seat that kind of wraps arround the back of the tank? I'll have to look at some pictures to figure it out. I know of a guy arround here who has an 04 or 05 F model, do those have the same tanks as an 02 and up E model? Either way, I can probally find the guy and take some measurements swap seats etc to see if I can get something to work for both styles and looks good.

Nobody has said anything abpout the price. I need to look into what materials and supplies would run me but is $150 a decent price? If there's enough interest I'll try to make it work with the stock cas cap, which should keep prices down. Would most of you want it just out of fiberglass or with a carbon fiber layer?

I think about 1/2" to 1" added to the top and sides all arround, if done right would still look pretty stoch and should add significant capacity, I'll probally go that route.

He would have to have propper plates lazer cut to use the stock cap...and I can have a plate cut out to mount the stock petcock.  Overflow can simply be molded into the tank with bit of copper tubing.

Nolan, let me know if you want the plates lazer cut, or if you have someplace that can do it I'll send you the plans.

$150 is NOT a decent price for a carbon fiber tank.  If you budget 1 gallon of resin, enough material to do the tank, plus the propper plates to have the caps and petcocks bolt up you're looking at nearly $150 just in materials.  If you were to make it out of polyester and fiberglass you could make money, but not out of epoxy and CF.

With a little deliberation I decided I'd do this for the TL crowd...since I have a TL tank handy I can use as a plug.  MY estimate right now sits at $390 shipped to the states (for the TL tank, but the GS tank won't be much different).

24d

ok so what's the difference?

Can anyone here send Nolan a newer tank so he can make the necessary adjustments to suit each?

'01+ is slightly taller, I believe (hence the increased capacity) and shaped differently where it meets the seat. As for mounting points, I understand that they're the same.