Ameer Randolph
Making a fiberglass motorcycle fuel tank is a challenging endeavour, and there are several factors to consider. Firstly, selecting the appropriate resin is crucial, as different types of resin have varying properties and suitability for fuel tanks. The process involves working with fiberglass and epoxy to seal the tank, ensuring it can withstand fuel without damaging the fiberglass. It is also important to address safety concerns, particularly regarding static electricity. Grounding the tank or adding a metal ground strap can help mitigate the risk of static discharge during fueling. Customizing a fuel tank requires careful planning and experimentation with different materials to achieve the desired outcome.
Characteristics and Values of a Fiberglass Motorcycle Fuel Tank
| Characteristics | Values |
|---|---|
| Materials | Fiberglass, resin, epoxy sealer, saran wrap, paste wax, fiberglass gel, body putty |
| Tools | English wheel |
| Process Steps | Dissolve foam, install fuel neck and cap, install threaded petcock bungs, seal with epoxy, sanding, smoothing, coat with sealer |
| Considerations | Safety concerns due to static electricity, compatibility with fuel type (e.g. California fuel, ethanol), durability in racing conditions |
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What You'll Learn
Choosing the right resin
Fuel Compatibility:
The resin you choose must be compatible with the type of fuel you plan to use. For example, if you intend to use kerosene fuel, epoxy resin is recommended. However, it's important to note that some resins may not be compatible with certain types of fuel, such as ethanol gas, which can dissolve the resin in fibreglass and cause operational issues.
Sealing and Safety:
The safety of your fibreglass fuel tank heavily relies on effective sealing. Epoxy is often recommended for sealing petcocks in fibreglass fuel tanks. It provides a strong seal and can be easily removed and reinstalled using a crescent wrench. Additionally, consider the overall safety of the tank. For example, race bikes with FRP tanks may require the use of a bladder due to crash durability concerns.
Resin Type and Workability:
Different types of resins are available, each with its advantages and disadvantages. While vinylester resin is said to resist the effects of alcohol in fuel, it is harder to work with, has a strong odour, and a limited shelf life. Other resin options, such as epoxy resin or polyester resin, may be more user-friendly and versatile.
Static Electricity Concerns:
Consider the potential for static electricity build-up when selecting a resin. This can be a safety concern, especially when filling the tank. Grounding the tank properly or adding a metal ground strap between the tank and the frame may help mitigate this issue.
Durability and Longevity:
Choose a resin that will provide a durable and long-lasting fuel tank. Consider the tank's resistance to cracks, leaks, and other forms of damage. Some resins may offer better impact resistance or flexibility, enhancing the overall durability of the fibreglass fuel tank.
When making a fibreglass motorcycle fuel tank, carefully consider the specific requirements of your project, the type of fuel you will use, and the safety standards you need to meet. Selecting the right resin will ensure the success and longevity of your custom fuel tank.
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Sealing the tank
Before sealing, it is important to prepare the tank surface. Sand the tank using a fine-grit sandpaper to create a smooth base for the sealant to adhere to. Remove any dust or debris generated during sanding with a tack cloth or a damp cloth. It is important to ensure that the tank is thoroughly cleaned and dried before proceeding to the next step.
Select an appropriate sealant for your fibreglass fuel tank. A common choice is epoxy sealer, which is known for its effectiveness in sealing fibreglass tanks. You can also consider using a product specifically designed for sealing fuel tanks, such as Caswell, which is compatible with fibreglass. Additionally, you may want to look for a sealant that can withstand the type of fuel you intend to use. For example, the "Blue" tank coating was found to be incompatible with California fuel, leading to the adoption of a new grey coating that performed well in long-term soaking tests.
Apply the sealant evenly to the prepared surface of the tank, following the instructions provided by the manufacturer of the sealant you have chosen. Ensure that you wear the appropriate personal protective equipment, such as gloves and a respirator, during the application process to avoid any contact with the chemicals. Allow the sealant to cure completely according to the manufacturer's instructions. This may take longer than the advertised curing time, so it is recommended to give it a couple of hours, if not more, to ensure it is fully cured.
After the sealant has cured, you can install the petcocks, which are the valves that control the flow of fuel. Thread the petcocks directly into the fibreglass and seal them with epoxy. Ensure that you do not get any epoxy in the fuel passage hole. A bead of epoxy may appear, which you should leave intact. Again, allow the epoxy to cure for a couple of hours, even if the advertised curing time is shorter.
Finally, test the seal of your fibreglass motorcycle fuel tank. Install the fuel neck and cap, along with any threaded inserts or bungs. Fill the tank with fuel and let it sit for a few weeks to ensure that the sealant holds. If there are no signs of leaks or issues, your fibreglass fuel tank is now ready for use.
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Petcocks and fuel necks
When making a fibreglass motorcycle fuel tank, one of the key considerations is the inclusion of petcocks and fuel necks. Petcocks, or petrol cocks, are valves that control the flow of fuel from the tank to the engine. They are essential components of the fuel system and need to be securely installed and sealed to prevent leaks.
There are different ways to install petcocks, but one common method is to thread them directly into the fibreglass tank. This involves cutting threads into the fibreglass to match the petcock threads. Once the petcock is threaded into the tank, a sealant is applied to create a tight seal and prevent leaks. A popular sealant option is epoxy, which provides a strong and durable seal. It is important to allow the epoxy adequate time to cure, typically a couple of hours, even if the epoxy is labelled as a "5-minute epoxy".
When installing the petcocks, it is also crucial to consider the fuel neck, which is the opening through which fuel is poured into the tank. The fuel neck should be positioned and sealed properly to ensure a tight connection with the fuel cap, preventing leaks and vapour emissions. Some people choose to install threaded inserts or bungs for the fuel neck and petcocks, which can then be sealed with fibreglass or epoxy.
It is worth noting that some fuel tanks may have specific requirements or regulations, especially for race bikes. For example, race bikes may be required to use a bladder inside the fuel tank to enhance crash durability. Additionally, static electricity discharge can be a concern, especially when filling the tank, so proper grounding is essential. This can be achieved by running a grounding strap from the tank to the frame or the negative terminal of the battery.
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Grounding the tank
When making a fibreglass motorcycle fuel tank, one of the most important considerations is safety, specifically concerning static electricity. Most fuel tanks are grounded in some way, often through a bolt. If you are concerned about static electricity, you can run a grounding strap from the tank to either the frame or the negative terminal on the battery.
Race bikes, for example, are not permitted to run FRP tanks without using a bladder due to their crash durability. To avoid this issue, you could bolt the tank to the frame through rubber isolators and add a metal ground strap between the tank and frame. This will help to dissipate any static charge that may build up due to air passing over the tank.
Another option is to use a fuel cell and create a cover out of fibreglass or carbon fibre, which would save time and bypass the static issue altogether. However, this method would result in a loss of useful volume due to the metal parts' simple form.
It is important to note that many dirt bikes and Triumph motorcycles have plastic tanks with no reported problems. Therefore, as long as your tank is properly grounded, you should not have any issues with static electricity.
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Dissolving the foam
When it comes to dissolving the foam in the process of making a fibreglass motorcycle fuel tank, there are a few key considerations and steps to follow. Firstly, it is important to protect the foam with a suitable material, such as Saran Wrap or paste wax. This step helps to ensure that the foam does not come into direct contact with the fuel, which could affect the fibreglass and resin.
Once the necessary precautions have been taken, you can begin the process of dissolving the foam. One approach is to use a solvent such as lighter fluid or acetone, which can help to break down the foam. It is important to exercise caution when working with these solvents and to follow the necessary safety procedures.
Before pouring fuel into the tank, it is advisable to coat the inside of the tank with a suitable sealer. This step helps to protect the fibreglass and resin from the fuel, ensuring that they are not damaged before sealing. It is also recommended to allow the sealer to cure for a few hours, or as directed by the manufacturer, to ensure its effectiveness.
After dissolving the foam, the next steps involve installing the fuel neck and cap, as well as the petcocks or threaded inserts. These components play a crucial role in ensuring the proper functioning of the fuel tank. It is important to refer to specific instructions and guidelines for your motorcycle model to ensure a precise and secure installation.
Finally, it is important to consider the sealing process for the petcocks. Similar to the previous sealing step, it is recommended to use an epoxy sealer for this purpose. Allow the epoxy to cure for a couple of hours, even if the package instructions suggest a shorter time frame. This ensures a strong and durable seal, preventing fuel leakage and ensuring the long-term functionality of your fibreglass motorcycle fuel tank.
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Frequently asked questions
There are a lot of different views on which resin to use for a fiberglass motorcycle fuel tank, and no definitive answer.
The best way to seal a fiberglass motorcycle fuel tank is with 5-minute epoxy. To remove petcocks, simply put a big crescent wrench to them and loosen. To re-install, reapply 5-minute epoxy all around the petcock threads and tighten.
Static electricity can be prevented by running a grounding strap from the tank to either the frame or the negative terminal on the battery.
It is recommended to use a mix of E10 50/50 with non-ethanol premium or aviation fuel.
To remove foam from a fiberglass motorcycle fuel tank, you can try dissolving it with lighter fluid or acetone.
