Rajan Wilcox
Fuel tanks for motorcycles are generally made of metal, such as steel or aluminium alloy, but there is a growing trend to use plastic, especially for lightweight motorcycles. The manufacturing process can be done by hand or mass-produced. The design of the fuel tank will depend on the style and capacity requirements of the bike, and the material used will determine how the tank is held together, with welding being the most straightforward method. The capacity of a fuel tank can vary from 5 litres to 20 litres depending on the model, with larger tanks providing greater riding distance per tankful.
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What You'll Learn
Design considerations: style, capacity, function
When designing a bike fuel tank, several considerations must be made regarding style, capacity, and function.
Style is an important factor in the design of a fuel tank, as it is often regarded as the 'face' of the motorcycle. The shape, size, and colour of the fuel tank contribute to the overall style and design of the bike, and can thus be a determining factor in a customer's first impression of the vehicle. A sleek and stylish fuel tank can enhance the bike's appearance and improve its manoeuvrability, increasing the rider's satisfaction. Additionally, the material used can also impact the style and overall aesthetics of the fuel tank.
Capacity, or the amount of fuel the tank can hold, is another crucial design consideration. The required capacity may depend on where the motorcycle will be ridden. For example, a bike intended for long-distance rides or off-road use may require a larger fuel tank to provide greater riding distance per tank. On the other hand, a smaller, more compact fuel tank may be preferred for sports bikes or racing bikes, where lightweight construction and manoeuvrability are prioritised.
The function of a fuel tank is not limited solely to holding fuel. It also serves as a secure area for the rider's knees to grip while riding, creating an important point of contact between the bike and the rider. The material and thickness of the fuel tank impact its function and durability. Steel, aluminium, or titanium tanks, for instance, are known for their lightness and strength, contributing to the bike's overall performance. Additionally, the manufacturing process, such as welding, must be considered to ensure the fuel tank is securely held together.
The production process and design of the fuel tank are closely intertwined. For instance, flangeless tanks, despite their aesthetic appeal, are less suited to mass production due to their complex manufacturing requirements. Similarly, the choice between hand-making a one-off fuel tank or mass-producing them will impact the final design and production process.
Ultimately, the design considerations of style, capacity, and function are interconnected and must work together to create a fuel tank that meets the rider's needs and expectations.
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Materials: steel, aluminium, plastic
Bike fuel tanks are typically handmade, which means they can be crafted from a variety of materials, including steel, aluminium, and plastic. Each material has its own advantages and disadvantages in terms of cost, durability, and performance.
Steel is a common choice for bike fuel tanks due to its affordability, ease of shaping, and welding. It is also highly durable, providing good abrasion resistance and preventing shattering or cracking when dented. Steel tanks can last for decades without significant issues. However, steel is susceptible to rust and corrosion, especially in certain environments, which can impact the aesthetics and functionality of the tank over time.
Aluminium is another option for fuel tanks. It is lightweight, easy to machine, and hammer, and highly resistant to rust. However, aluminium is more expensive than steel and requires thicker material for fuel tanks. It is also harder to work with, especially during welding, as it demands specialised equipment and techniques.
Plastic fuel tanks are often chosen for their lightweight and flexible nature. They are made from various plastic materials, including polypropylene, regrind plastic, high-density polyethylene, ethyl vinyl alcohol, and plastic adhesives. The thickness of plastic fuel tanks is essential for their durability, with tanks made from high-density polyethylene offering increased strength and a longer lifespan. Plastic tanks, however, may be susceptible to expansion and contraction due to fuel type, heat, and other factors, which can lead to safety concerns in the event of a crash or slide.
The choice of material for bike fuel tanks depends on various factors, including cost, ease of manufacturing, durability, and visual appeal. Each material has its own unique set of advantages and drawbacks, influencing the decision-making process for manufacturers and consumers alike.
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Manufacturing: handmade vs mass-produced
Motorcycle fuel tanks are fundamental to the machine's operation, storing and supplying gasoline to the engine. They are also a defining feature of a motorcycle's design, with the exterior appearance and shape of the tank's knee grip area playing a crucial role in the rider's experience. Given these important roles, the manufacturing process for fuel tanks is a key consideration.
Handmade fuel tanks are often crafted by artisans using traditional techniques. This process allows for customization and unique designs that may better match the bike's style and functionality requirements. For example, a handmade tank can be tailored to a specific capacity, ensuring the motorcycle is suitable for the intended riding conditions. The choice of material and its thickness is another important consideration in handmade tanks, with options including steel, aluminium, copper, or alloys. While welding is a common method for joining the pieces together, the process must be carefully managed to minimise welds and maintain the desired shape.
In contrast, mass-produced fuel tanks are created using standardised processes and computer simulations to ensure consistency and efficiency. Large companies like Yamaha utilise computer simulations and advanced machinery to optimise production. For example, Yamaha uses a massive press machine to form the steel sheet metal into the desired shape for their MT-Series tanks. While mass production benefits from increased speed and reduced costs, it may lack the customisability and unique style of handmade tanks.
The exterior finish of a fuel tank is a critical aspect, regardless of the manufacturing method. A multi-step process is typically employed, involving tactile checks by craftsmen who use their palms to detect even the tiniest imperfections. Polinet cloth polishing inspections are also conducted to identify minute flaws in the surface. These inspections ensure that the fuel tank meets the strict quality standards before being certified as complete.
The choice between handmade and mass-produced fuel tanks depends on various factors. Handmade tanks offer customisation, unique designs, and the potential for higher-end materials, whereas mass-produced tanks benefit from standardised processes, increased production speed, and reduced costs. Ultimately, the decision is influenced by the specific requirements, budget, and desired style of the motorcycle and its owner.
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Assembly: welding, mounting, positioning
The assembly process for a bike fuel tank involves welding, mounting, and positioning. Here is a detailed guide to each of these steps:
Welding
Welding is a common process used to join the parts of a fuel tank together. When hand-making a fuel tank, it is essential to minimise the number of welds required, as this simplifies the process. The material chosen for the tank will influence the welding process, with options including steel, aluminium, or copper.
Mounting
Fuel tanks can be mounted in various positions on a bike, depending on the design and type of bike. For example, some fuel tanks are located under the floorboards, while others are positioned under the seat. Sports bikes often have fuel tanks mounted directly on the bike, contributing to the bike's aesthetics and providing a secure area for the rider's knees.
Positioning
The positioning of the fuel tank is crucial, as it affects the bike's overall aesthetics and functionality. The shape, size, and colour of the fuel tank are determining factors in the bike's design and can enhance the riding experience. For instance, a sleek and lightweight fuel tank can improve manoeuvrability and foster a closer relationship between the rider and their machine.
Final Assembly
To ensure a smooth finish on the fuel tank, a English wheel is used for final smoothing. The fuel tank is then placed on a "buck," a wooden form that helps to create the desired final shape. This process may vary depending on whether the fuel tank is handmade or mass-produced, with mass-produced tanks often prioritising speed and efficiency over safety.
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Maintenance: safety, sealing, inspection
Maintenance, safety, sealing, and inspection are all critical components of owning a motorcycle. Regular inspections of your fuel tank are essential to keeping your bike running and avoiding costly repairs. Before inspecting your tank, ensure it is in a clear area, away from safety hazards. If your tank is static, ensure it is adequately grounded (electrically earthed) before performing any operational tests.
You should visually inspect your tank for leaks at least once a week. Keeping the area around your tank clear of debris and vegetation makes it easier to spot leaks early on. Check for water or product in the interstitial space (containment area) weekly, and remove any rainwater, diesel, or other liquids that may have accumulated. A trained person with appropriate PPE should handle this and dispose of any waste as hazardous material, following local regulations.
It is also important to regularly check your fuel levels. Running on a near-empty tank can cause sediment to form at the bottom, blocking and damaging pumps and equipment. Debris and sludge can clog filters, so regular checks and cleaning are necessary. Mesh filters (strainers) should be part of your regular inspections, and you may need to remove the flexible dip pipe from the cabinet to access internal strainers. If you have a water filter, consider replacing it at the same time.
To maintain fuel flow, inspect the pumping equipment, vents, and valves regularly. Remove filler caps and clean threads with a wire brush if necessary. Prevent rust by applying a small amount of lithium grease to these areas. Check the gasket at the bottom of the cap and ensure a good seal before refitting. Vents, fittings, and pipelines require a visual check for leaks or damage every week, and a physical check for bolt tightness, paint deterioration, and the general condition of pumps, vents, and valves every six months. Hinges on the cabinet cover or door should be lubricated to avoid rust and wear and tear.
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Frequently asked questions
Motorcycle fuel tanks are generally made of metal, such as steel or aluminium alloy. However, there is a growing trend to use plastic, especially for lightweight motorcycles.
There are two main methods: hand-making a one-off tank or mass production. The handmade method involves welding metal sheets together, while the mass-produced method involves using machines such as a shrinker/stretch machine and a planishing hammer.
The capacity of a motorcycle fuel tank depends on the model and the intended use of the motorcycle. For example, a motorcycle designed for long-distance travel would require a larger fuel tank than one designed for urban commuting.
The shell of a motorcycle fuel tank serves two main purposes. Firstly, it needs to be durable to withstand external impacts and prevent leaks. Secondly, it can also serve an aesthetic decorative purpose, enhancing the appearance of the motorcycle.
Safety measures such as good sealing and reasonable placement are crucial for fuel tank design. The filling port should be equipped with a lockable safety cap to prevent moisture, dust, and impurities from contaminating the fuel.
