Homemade fibreglass fuel tanks?

[Padmei]

Thinking of making one. Been looking at info on the net - will it all end up in a massive fireball?
What do you reckon?

[Ocean1]

Snot difficult. You can get special resin for fuel tanks but while I'm not sure what the difference is I've made several tanks with common polyester resin without any problems.

[Mike.Gayner]

This guy made one for his Sabre project:
https://www.youtube.com/playlist?list=PL8SLiVEQM9KNBccNx4p2W9W5ggKPFy30w

Looks fairly straight forward, lots of hours and fiddling involved. More than I could be bothered with. In an accident I'd say a glass tank is extremely likely to crack, but I doubt it'd be much of an issue.

[ducatilover]

Very, very time consuming. If you're worried about the whole fire and/or leaks issue, either bladder it or run POR15 tank sealer :yes:
Kevlar mat as a middle layer is never a terrible idea either to eliminate massive smashing and leaking after impact, or cover it in tampons to absorb spills (I have seen the TV ads!)

[Kickaha]

Pretty sure Eurodave used to make them, PM him and he might give you some info

[AllanB]

All that work on the tank and he painted it like that ....:confused:

[Steve Gauge]

bugger you for posting that link now ill have to watch the lot ,half way through - that tank looks like a big job .
the guy does a good job of keeping it all moving along

[AllanB]

Agree - I spend a bit of this arvo flicking through just the fiberglass bits - comes out well but a shit load of work. Think I'd beat up alloy.

I did not see any pressure testing of the tank.

Also - considering the time involved ..... a Honda Sabre .....

[ducatilover]

Agree - I spend a bit of this arvo flicking through just the fiberglass bits - comes out well but a shit load of work. Think I'd beat up alloy.

I did not see any pressure testing of the tank.

Also - considering the time involved ..... a Honda Sabre .....

Your tank shouldn't be under pressure anyway ;)
I'd rather glass then beat alloy, unless you're a boss with an english wheel

[Ocean1]

Your tank shouldn't be under pressure anyway ;)
I'd rather glass then beat alloy, unless you're a boss with an english wheel

And if you're going to make alloy shells then instead of welding them together you could bolt them, add a few simple mounts and roto-mould a nice HDPE tank which won't burn or dent.

[ducatilover]

And if you're going to make alloy shells then instead of welding them together you could bolt them, add a few simple mounts and roto-mould a nice HDPE tank which won't burn or dent.

Pretty sure if you are worried about burning, or denting a tank, the tank is the least of your concerns. :shutup: I end over ended my Kawasaki several times at neat 100 and the tank wasn't too bad to sort out :Police:

[Ocean1]

Pretty sure if you are worried about burning, or denting a tank, the tank is the least of your concerns. :shutup: I end over ended my Kawasaki several times at neat 100 and the tank wasn't too bad to sort out :Police:

*Shrugs* If you've got the time to fuck about making shit you might as well do it right, eh?

I mean if you're rebuilding a Montessa Cota then by all means use glass. Polished alloy for a classic by all means but of all the tanks I've fuched the vast majority have been dirt bikes that should have been plastic... and weren't.

[Padmei]

All good shit thanks guys. I know it'd be a bit of work but the whole bike is a project.
My initial desire was to make a metal/ alloy tank but without an english wheel & years of experience doing it it will end up like shit. Glass I'm not too worried about. the bike (old BMW)isn't gonna be anything flash when finished & will prob get ridiculed anyway.

My ideal tank style is the old KZ one - very stylish in my books. Prob easier to make a mold off an existing one..... actually in saying that I know where there are a few in a guys workshop.....hmmm

[ducatilover]

All good shit thanks guys. I know it'd be a bit of work but the whole bike is a project.
My initial desire was to make a metal/ alloy tank but without an english wheel & years of experience doing it it will end up like shit. Glass I'm not too worried about. the bike (old BMW)isn't gonna be anything flash when finished & will prob get ridiculed anyway.

My ideal tank style is the old KZ one - very stylish in my books. Prob easier to make a mold off an existing one..... actually in saying that I know where there are a few in a guys workshop.....hmmm

If you're just knocking up a one off tank, just make a sacrificial foam mold and go from there. Paint the resin on the glass matting before laying too, many people just lay it on then paint the resin over it, which is a poor way to do it and makes it weak

[Ocean1]

If you're just knocking up a one off tank, just make a sacrificial foam mold and go from there. Paint the resin on the glass matting before laying too, many people just lay it on then paint the resin over it, which is a poor way to do it and makes it weak

Unless you're using CSM, (and you probably should be) which is loosely stuck together with an agent that polyester resin dissolves.

[ducatilover]

Unless you're using CSM, (and you probably should be) which is loosely stuck together with an agent that polyester resin dissolves.

^ this man knows many things and should be listened to

[Padmei]

CSM? I googled it & certified scrum maker came up:(

I was planning on using polystyrene & epoxy resin. I have a couple of mates in the kayak building game with a vacuum bag outfit. Reckon I'd need to por15 it or is our gas ok over here?

[ducatilover]

CSM? I googled it & certified scrum maker came up:(

I was planning on using polystyrene & epoxy resin. I have a couple of mates in the kayak building game with a vacuum bag outfit. Reckon I'd need to por15 it or is our gas ok over here?

Chopped strand matt
Chinese Sexual Magic
Probably the first one
I'd POR15 it just in case you had some radom strands flapping around in it and just to be double sure.

[husaberg]

I posted ages ago how to do it with emulsion paint over polystyrene it was in mcm years ago for a bantam project I would guess it was on the chassis thread if I can be assed to do a link on the tablet I will l8r
http://www.kiwibiker.co.nz/forums/showthread.php/145224-Race-chassis?p=1130349123#post1130349123

[Ocean1]

CSM? I googled it & certified scrum maker came up:(

I was planning on using polystyrene & epoxy resin. I have a couple of mates in the kayak building game with a vacuum bag outfit. Reckon I'd need to por15 it or is our gas ok over here?


Chopped strand matt
Chinese Sexual Magic
Probably the first one
I'd POR15 it just in case you had some radom strands flapping around in it and just to be double sure.

Sorry, I hate techno bullshit acronyms and abbreviations, I should know better.

Yes, chopped strand mat. It's cut fibres laid randomly and stuck together with bare minimum of a soluble glue, (used to be starch based). It's main advantage is that on contact with polyester resins the glue dissolves and the individual fibres are free to slide across each other, making it easy to mould over non-developable surfaces without pleats or tears.

If you're using epoxy you need a completely different procedure and different materials. Your Kayak dudes will be using probably a mixture of woven E-glass and or carbon and cutting it very carefully into panels and strips and then vacuum-bagging the lot under peel-ply.

You can do either, but without experience and access to some reasonably expensive kit you're probably better to stick with polyester. Do not, for example use 'er inodoors sucky-motor to vacuum bag your layup. Especially if there's the slightest hint of acetone around.

[Ocean1]

I posted ages ago how to do it with emulsion paint over polystyrene it was in mcm years ago for a bantam project I would guess it was on the chassis thread if I can be assed to do a link on the tablet I will l8r
http://www.kiwibiker.co.nz/forums/showthread.php/145224-Race-chassis?p=1130349123#post1130349123

Emulsion paint = Acrylic?

[AllanB]

Alloy for me one day when I have the project bike (ie when I have money). Reckon I'd form the shape in wood and use it as a template to beat the alloy over. I've one of those Biker Build-Off DVD's and a Aussie builder does this with all the bodywork for a chop he makes. Fair bit of work but achievable with relatively simple tools.


I was dreaming on a USA tool site recently (Harbor Fright if I remember) English Wheels etc are disgustingly cheap there .... actually somewhere at home I have a NZ magazine on how to DIY make one.

[husaberg]

Emulsion paint = Acrylic?

Not really sure the poms use the term I remember it from the Brit version of trading rooms pretty sure you could use glad wrap as well if you wanted

[Ocean1]

Not really sure the poms use the term I remember it from the Brit version of trading rooms pretty sure you could use glad wrap as well if you wanted

Ah yes, I remember my landlord in London bunging a coat of emulsion on the flat.

I've used cheap acrylic house paint. It don't melt the syrene and you get a reasonably high-build, so it works well for male moulds. Would stay in the tank when the styrene's washed out of a one piece mould though, which is one reason a two piece mould may be a better idea.

[Padmei]

just deleted the last 10mins typing Fck it.

I'm getting the good oil now.
So I can use poly (I'd prefer to as that's what my mates use - they have epoxy but in small quantities) if I paint the mold with acrylic - good
I am planning on doing a two part mold .

Allan b I know what you mean about harbour freight - shitloads of stuff dirt cheap.

If there's any more magic keep it coming.

[Ocean1]

just deleted the last 10mins typing Fck it.

I'm getting the good oil now.
So I can use poly (I'd prefer to as that's what my mates use - they have epoxy but in small quantities) if I paint the mold with acrylic - good
I am planning on doing a two part mold .

Allan b I know what you mean about harbour freight - shitloads of stuff dirt cheap.

If there's any more magic keep it coming.

Boat pox.

If you leave un-wetted fibres exposed at the surface of a layup osmosis will cause any available liquid to pump up the fibre under extreme pressure and slowly explode the whole area.

Half of the cowboy-built glass fizzboats made in the early days ended up getting badly patched, sold, patched again and sold....

Another good reason to make tanks in 2 halves, you get to closely inspect both inside and outside surfaces and fix any issues. Look closely, dry fibres are very difficult to see. POR15 might be a good belt and braces idea but I've never used it in a glass tank, check the tech literature.

[ducatilover]

Boat pox.

If you leave un-wetted fibres exposed at the surface of a layup osmosis will cause any available liquid to pump up the fibre under extreme pressure and slowly explode the whole area.

Half of the cowboy-built glass fizzboats made in the early days ended up getting badly patched, sold, patched again and sold....

Another good reason to make tanks in 2 halves, you get to closely inspect both inside and outside surfaces and fix any issues. Look closely, dry fibres are very difficult to see. POR15 might be a good belt and braces idea but I've never used it in a glass tank, check the tech literature.
I've known of a few people running the POR15 in glass tanks long term with no issues and have never heard any actual issues :yes:

[imdying]

Vinylester would probably be more suitable, commonly used on chemical tanks etc. Osmosis is definitely a concern.

[husaberg]

Surfboards are a good source of high desinty if you need some surfers often have broken boards easier to shape too nice finish possible