Manual

Okay, just a limp across town to a friend's afternoon barbecue, but still a real enough ride to shake it through some gears and attempt ...

OK, finally got the moto specific fuel line from J&P. It's much more flexible than the automotive kind while still having some subs...

OK, got back to some progress on the bike. Used the Caswell snot to seal the interior, hope it holds. Been off line because I've got a...

Here's how it looks now

The forward mounting brackets worked out okay so I reinforced them and sanded them down a bit. Now it is time to get the rear bracket sorte...

Had the hardest time trying to figure out how to place the forward mounting tabs for the tank. The tabs are nothing more than a "C...

OK, mixed another slury of the milled glass fibers with the slow cure epoxy and laid a bead along the interfaces. Got a lot of squeeze-out ...

OK, I talked to the tank sealer guys at Caswell and they said I ought to scuff up the insides of the tank since I can and it'd help adhe...

looks like they'll bolt right on no probs. You can see on the right side how the positioning plates formed the epoxy/paste mixture into...

OK, Milled glass fibers came in the mail and so now onto mixing into a thick slurry with epoxy to finish off the T-nuts that mount the petco...

OK, managed to epoxy on a few "T" nuts to the bottom piece which will attach the petcock valves. I've positioned them with a ...

I probably should have let the thing cure a bit longer in the mold but it looked solid enough and I just couldn't wait. I'm that wa...

Never made a gas tank before. It's obvious I'm way over my head here. Anyway, let's begin making the top part. I chose to use ...

From the Caferacer.net board: Tank lining with composites seems to be a hotly contested subject of late especially with ethanol based fuels...

OK, Now I'm cleaning up the edges of the mold and am holding it together with some old 5mm machine screws I had: I left about an inch of...

OK, well I built up all the other facets much like the first and this morning used a butter knife to pry them apart. It's quite a noisy...

After the glass had cured, I tried pulling the weirs used in it's construction. Sadly the adhesive from the glue gun stuck a little too...

One step at a time! I used a slurry of milled glass fibers and epoxy to get into the nooks and crannies before doing the primary layup usin...

8 layers of 5.6 oz "S" glass ends up being roughly 1/16" thick. Hmmm...I'd like it to be about twice as thick just for p...

So I'll apply glass/resin to the mold and a ways up on the weirs to build some flanges for the mold pieces to bolt together with. This ...