Yeah, I was thinking that it may cost a bit more than that. I haven't priced materials yet. Maybee I'll use polyester resin, which will work just as well with the fiberglass, but I don't know about the carbon fiber. Either way, it shouldn't take a full gallon, but I'll see on my first one. I'm going to make my first one out of fiberglass to make sure it turns out okay, then I'll get some carbon fiber only if there's interest. I've also seen fiberglass that's dyed to look like carbon fiber and is way cheaper, could try that too.

Have you done this or much other fiberglass molding Mac? Where did you get those drawings for the gas cap ring? If I could get those from you it would make my job a bit easier. I don't think I'll need to have the stuff laser cut though, I haver a drill press and a bandsaw, that should do the job just fine.

As for the petcock, I don't think I'll have it take the stock one, I'll do something different that's easy to turn off by hand, so that people can either use it alone and run it straight to the carbs or use itr with the frame molunted automatic petcock.

In the next couple of days I should be able to check out an 05 model to see the possibility of one tank working and looking good on all models. I can see that there is definatly some interest! That should help bring the price down, I'll have to figure out a final price once I've built one and figure out what materials will cost, and how much labor will cost.

I doa  lot of carbon fiber and fiberglass work.  I've built fuel cells before, but it's always been on a private contract.  I've only sold cosmetic c/f stuff, and heat shields, on a commercial level.

I would suggest having the fittings lazer-cut.  They're be perfect and it'll only cost about $50, plus shipping, to do the gas tank ring and the two pieces for the petcock.  All I really did was trace out the gas cap and bolt pattern.  I'd have two rings cut to match the gas cap assembly, but carve one with the bolt holes a little bigger, thread the other.  Then add three or four more bolt holes so that the tw templates can be sanwiched together, with the tank's material in between them.  Then bolt the cap down.

Similar for the petcock...better for the petcock, even.  Cut out two 2" X 4" pieces of 1/2" mild plate.  Carve a 1" X 2" chunk out of one, and drill and tap the other for the stock petcock.  Then add 6 holes for threading so that you can bolt these two together the same was as the cap...stock petcock bolts right up.  I'll post up drawings here in a bit.

As for cost, no it shouldn't take an entire gallon for a project like this.  I'd expect between half and three quarter to allow for all the material sauration and sealing with epoxy.  The thing is that with this stuff it's hard to utilize left overs for other projects.  You also have to take "accidents" into consideration.  It'll almost be mandate to buy a new gallon for every customer and quality epoxy's are going to run you about $100 a gallon (shipped).

I would also suggest sticking with epoxy.  Polyester WILL break down under fuel without lining and relining every so often.  I use gasoline to clean my brushes and polyester guns.

Carbon fiber and fiberglass are pretty universal between polyester and epoxy.  The difference is all in the material, and that's all in carbon being lighter and stronger.  Fiberglass is cheaper, but, in my opinion, the price difference isn't that tremendous when the over all project is done.

Quote from: NiceGuysFinishLast on October 25, 2006, 01:43:28 PM
'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.

01+ tanks are wider. Both are same height. 01+ does not have the front mounts for the side panels.

Correct about the shape where the seat fits, 01+ has a depression for the seat to fit in at the thigh area. The other year seat sorta can fit but not really. The 89-00 seat will fit better on the 01+ than the 01+ on the 89-00.

It has been a while since I mixed and matched the years.

Mak is correct... no friggin way you can do it for 150

if it is bigger....easier to damage in a light spill...destroy

YSR 50 fiberglass tanks go for 300 on e-bay as fast as they are listed....last time i looked

make one for yourself...... most people will not buy them

there is also the liability concern..... if the bike tips over next to someone who is smoking...explosion....you get sue'd as the manufacturer

Quotethere is also the liability concern..... if the bike tips over next to someone who is smoking...explosion....you get sue'd as the manufacturer

Not so.  Any modification to the fuel tank or fuel cell, not done by a certified mechanic with parts not from the original manufacturer or an authorized source, are not approved for use on US roads.  Nolan, as a manufacturer, bears no responsibillity, so long as he makes it clear that his tanks have not been approved for use by anyone other than himself.

Has anyone ever thought about using an older rusted out tank as a shell? Cut the bottom out and find a suitable plastic bladder to use underneath?

Average it's been though of...it serves no advantage save a rust-free enviroment.

[e3

Quote from: makenzie71 on October 25, 2006, 07:40:36 PM

Quotethere is also the liability concern..... if the bike tips over next to someone who is smoking...explosion....you get sue'd as the manufacturer

Not so.  Any modification to the fuel tank or fuel cell, not done by a certified mechanic with parts not from the original manufacturer or an authorized source, are not approved for use on US roads.  Nolan, as a manufacturer, bears no responsibillity, so long as he makes it clear that his tanks have not been approved for use by anyone other than himself.

Yeah like that would really hold up in court. If he sells one, then he knows it could be used by someone else so he is then liable. Wavers to not really mean anything.

Quote from: Wrecent_Wryder on October 26, 2006, 04:04:37 AM

Quote from: dgyver on October 25, 2006, 03:09:23 PM

The 89-00 seat will fit better on the 01+ than the 01+ on the 89-00.

Not to threadjack, but are you saying the earlier seat fits the later bikes, or are you just referring to the tank?  I've seen the question of whether the pre-'01 Corbin seat could be made to fit the later bikes more than once, but I've never seen an answer.

Yes it can fit the tank...but it will look like crap.

Quote from: dgyver on October 26, 2006, 05:03:39 AM

Quote from: makenzie71 on October 25, 2006, 07:40:36 PM

Quotethere is also the liability concern..... if the bike tips over next to someone who is smoking...explosion....you get sue'd as the manufacturer

Not so.  Any modification to the fuel tank or fuel cell, not done by a certified mechanic with parts not from the original manufacturer or an authorized source, are not approved for use on US roads.  Nolan, as a manufacturer, bears no responsibillity, so long as he makes it clear that his tanks have not been approved for use by anyone other than himself.

Yeah like that would really hold up in court. If he sells one, then he knows it could be used by someone else so he is then liable. Wavers to not really mean anything.

"For Off Road Use Only". Use at own risk.

There, no need for DOT approval then, and that should take care of any pesky lawsuits.

^ditto.  It doesn't even have to be printed ON the product...otherwise people like Pilot and Hella would be getting sued left and right.  Nohere on my HElla 500's does it say "off road use only" but right there on the package it does.

My brother and I would definitely be interested in a 89-01 version of this tank.  Especially at that 150 price tag...

Let me know if you decide to make them, we're already ready to order 

Quote from: makenzie71 on October 26, 2006, 02:10:51 AM
Average it's been though of...it serves no advantage save a rust-free enviroment.

Thats the point though, isn't it? 

Well though I don't want to step on Nolan's toes, I can have something whipped up in pretty short order (the GS has such a nice tank for this stuff).  There's a catch with me, though:

First, I can't do it for $150...you're looking at $300~350.
Second, I need a stock tank sent to me as core.  +$40 if you don't have a stock tank.
~tank can be in any condition...dents, rust, whatever...I'll be casting the stock filler and petcock flanges into the new tanks

Now, I can make the a stock replacement tank from fiberglass for $175, but I still need the core.

Also, I can make the fiberglass tank, but wrap the outside in carbon, for about $225.


~~Also, the bladder idea has many flaws.  The "rust free enviroment" is severely outweighed.

Are you still selling those slip ons too?

I sell a slip on flange and muffler, and the high-mount half-exhaust.

Where can I see a shot of the high mount half exhaust (preferably installed on a bike)?  I only see the carbon fiber slipon on your site.

http://gstwins.com/gsboard/index.php?topic=31343.0