aluminium gas tank

can someone help me out with blueprints to the super duke gas tank i found a place that is willing to make aluminium gas tank for the sd he has all cnc cutters ,benders so a blueprint or cad drawing would be great so i can get a price that shitty usa gas in ny is eating my tank so this will fix the tank for good

Do you have any indication of cost and could the tank be made larger?
Sorry no help on the CAD CAM drawings.

I've heard of an outfit in Japan that builds unpainted aluminium tanks for a number of different European sportbikes. They are expensive as heck though at about $2,000 USD for an unfinished bare aluminium tank. Caswell coating is certainly a more economical option but there's no guarantee it will hold up forever like an aluminium tank will. I'm due to finally get my coated replacement tank back next week. I don't know where your fabricator is but if they were in Northern VA, USA I'd be happy to take my old tank with the mumps to him to use for measurements.......although we certainly wouldn't want him to recreate the mumps in the aluminium tank! haha

Xmoto,

If your key concern is fuel eating the tank, try GTS 1750 gas tank sealer from www.caswelleurope.co.uk , contact them to see if it will work in plastic tanks, its great on metal and fibreglass.

There is a US arm of Caswell, you would need to contact them to see if they stock GTS1750.

thank's for all the help guy's keep them coming the place is in florida boyd welding he make's tanks for boat's airplain's racecar's anything and got back to me a.s.a.p and see's this as a great move as a lot of my brother sd and motorcycle rider's will be in need of a tank as gas go's to E-85 .i have asked my ktm dealer about the caswell tank sealer he also sell's ducati to and found ducati will not warrantie any tank with a sealer in it and think's ktm will do the same.we all hope ktm will do a run of tank's made of polyethylene like the dirtbike tank's but i have little hope of this happening so i will keep looking for a aluminium tank .if any sd owners live in florida stop over to boyd welding and show of your tank to start this ball rolling. i will send photo's to them but a sd sitting on his door step in priceless thanks steve

ok willh this is what i had in mind there were two one that did away with the drop downs around the air box this would free up airflow for the mh airbox and the bike will run cooler and to make up for lose of fuel widen the tank by 6inch's and make the fins as one with the gas tank so they hold gas to with a nice paint job you would never know the fin's were part of the tank as for the top of the tank rase it up 2inch's will have to keep watch for the handlebars as not to hit the tank and keep the center bend on top of the tank with no step's the filler cap unit i can make and you can holesaw out the top of the tank and drop it in and weld it up sam for the fuel pump i will try to draw somethig up i am no artist but my boss is i think this will make a better tank and not hurt the look's to much what do think willh i live in ny so your to farr and i hear you have some good beer up there worth a road trip if needed

A fiberglass tank made with http://www.engineeringtoolbox.com/chemi ... d_785.html may be the cheapest answer. If there is a real need for replacement tanks for the masses with road legal appeal and a realistic price tag then the dirtbike material tanks would be best. Sent an email to CAcycleworks to find out the requirements for a run.

or these guys, I have one of their tanks on my dirt bike.

http://imsproducts.com/Products.cfm?Man ... e&tyd=true

Artist http://www.thetankshop.com/

I am all ears.

There are companies that scan stuff and give you an STL file, I've seen software that can peel objects so you can create a pattern, in fact one of my suppliers does this as a service

I like the idea and I was actually thinking of making one in the same shape as the original when I find the time. One of the things I would do is add more space where the fuel pump is to get more fuel in the tank.

On the other hand I don't know if every one is too polite or so but the alu above is really ugly!!!
I admire the skills and so but man it's ugly... not talking about colour or so but the shape... it hurts my eyes. Sorry!

Totally agree! Looks horrible but I respect the craftsmanship of the builder.

Pretty sure I saw that aluminium bike when it turned up at KTM Centre Hemel Hempstead a few years back - it looks worse in the flesh...

Are we getting too polite around here and caring about others feelings? ehehee

The concept is of making aluminium tank is good to get rid of the problems around ethanol mix etc, and the tank itself it's not all that bad ( altough it's not beautiful, it keeps the original form's ) but the rest is not good.

Would have been prettier to make supports for the original plastics and keep the front end and rear R plastics.

I am currious about the weight of the tank + side panel...

If he didn't use thin aluminium it should weight more than the plastic one which is not that heavy.

It has an importance because tank is high so weight here change gravity center and so agility...

So it could be cool to compare standard and alu ones

What puts me off having a go is probably legal mumbo jumbo too about bursting if you have a crash or so.

Maybe a die press ($$$$)...two halves with an offset filler hole, then weld down the center like Husqvarna used to do. Beautiful paint & look...until you fall down and go boom!!!

This is much nicer! (It's for an RC8 though)

http://www.thetankshop.com/

http://www.boydwelding.com/?gclid=CLHVu ... Ogod6BcAZg

more

http://www.wbo-racing.de/index.php?page ... &Itemid=47

http://www.dimecitycycles.com/vintage-c ... tank1.html

http://www.flashcustoms.co.uk/

http://www.klpracing.com/

http://www.holtworks.co.uk/

http://www.imsproducts.com/AboutUs/

Search terms "ducati aluminium fuel tank"

http://www.ducatiuk.com/accessories/sup ... 1/index.do

Underside: http://www.ducati.ms/forums/77-sport-cl ... ks-26.html (see 4th post down)

http://www.emotouk.com/ducati1098/alumi ... eltank.htm

The above links, I know are for Ducatis, however this proves two things:

1. It is clearly possible to stamp complex sub sections (reduced labour) in aluminium prior to welding and completion in terms of mass (large volume) production.
2. The SDR I acquired on PCP was a brand new machine - it's an insult to then have to pay any extra to fix this problem from the factory (a problem KTM are fully aware of but won't subsidise).

In fact it's an insult to anyone, irrespective of the age/mileage of bike. I'm not annoyed with this post, simply saddened - let's face it, unless the PA6 Nylon scenario is fixed for good then this scales up into an absolute nightmare in terms of costs and turn around.

I'm certainly not trying to be a killjoy either - let's face facts, it's a fuel tank. I don't care what it's made from, I want it to work as it should and I don't want to have to explore expensive alternatives for peace of mind.

Someone is liable, not you, not me & I want them to finance the rectification. I don't see why you guys should be expected to finance your own resolve, at all. 10/10 for effort though & as this is a productive and informed forum, I wouldn't bother typing this if I felt it would be ignored so please take my oppressive stance with a pinch of optimism.

Not too long now & maybe, who knows, what result we can all look forward to in the not too distant future.

Has anyone tried cutting away the bottom of a factory plastic tank, fabricating an aluminium internal tank, and refitting the hollowed plastic shell from the original over the new aluminium tank? I want to do this but do not have the welding skills yet. It would look stock but could retain dimensional stability at the mounting points and take a lot less finish work than it would require to make an aluminium tank look nice. If the aluminium tank included the tank side panel mounts, that'd be even better and might give more fuel capacity. I am going to pursue a new tank from KTM NA, but I know expansion of that tank will happen in time and really want a permanent solution.