Mercedes Mullins
Motorcycle fuel tanks are typically made from steel, although some manufacturers use plastic. Steel is cheaper and easier to work with than other metals, and while steel tanks can rust, this usually isn't a problem for the first owner of the bike. Plastic tanks are more common on dirt bikes, but they can be damaged by ethanol in fuel, causing them to expand and contract. Aluminium is another option, but it is expensive and difficult to work with, requiring specialised equipment for welding.
| Characteristics | Values |
|---|---|
| Material | Steel, aluminium, plastic |
| Design | Style, capacity, form, thickness, smoothness |
| Manufacturing Process | Hand-made, mass-produced |
| Safety | Risk of rupture, fuel contamination, rust, deformation |
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What You'll Learn
Steel vs. aluminium
Motorcycle fuel tanks are typically made of steel, although aluminium and plastic tanks are also available. Steel is favoured by manufacturers because it is cheap, easy to weld, and easy to shape. However, steel tanks are prone to rust, which is a concern for motorcyclists.
Aluminium is a more expensive option than steel, and it is harder to work with. It requires thicker material, and a specialised alternating current electrode to weld it properly. However, aluminium is 2.5 times lighter than steel, highly resistant to rust, and easy to machine and hammer.
Aluminium is a popular choice for aftermarket modifications, and it is often used in choppers and cafe racers. It is also favoured by those who want to avoid the hassle of dealing with rust. While aluminium does corrode in the presence of salt and alkaline dust, this can be mitigated by painting the surface.
Plastic fuel tanks are another alternative, although they have been known to have issues with certain types of fuel, such as ethanol-treated fuel, which can cause the tanks to expand and contract. Plastic tanks are also more likely to rupture in the event of a crash, which can lead to fuel leakage and potential combustion. However, plastic tanks are commonly used in dirt bikes and are generally durable, with minimal heat deformation.
Overall, the choice between steel and aluminium fuel tanks depends on various factors, including cost, ease of manufacturing, weight, and resistance to rust and corrosion. Steel is the more common choice for motorcycle fuel tanks due to its affordability and ease of use, while aluminium is favoured in certain aftermarket and specialty applications where weight reduction and rust resistance are priorities.
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Plastic tanks
Plastic motorcycle fuel tanks are made from materials like polyethylene crosslink, which provides extra strength and durability. They are more common on dirt bikes and some higher-end bikes. Plastic tanks are chosen by manufacturers to cut costs, but this can come at the expense of safety and durability.
However, some riders have disputed these claims, stating that plastic tanks are more durable than imagined. They argue that heat deformation is minimal, and the risk of sliding on the pavement is mitigated by the frame, which prevents the bike from sliding directly on the tank.
Despite these counterarguments, the primary concern with plastic tanks remains the potential for fuel leakage and the associated safety hazards. Manufacturers must carefully consider the advantages and disadvantages of using plastic for fuel tanks to ensure the safety and satisfaction of their customers.
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Handmade vs. mass-produced
Motorcycle fuel tanks are typically handmade, a process that involves blow moulding. This technique, which was adapted from glass blowing, is used to create the hollow body of the tank. The first machine for this process was created by Hanoch Ferngren and William Kopitke and sold to the Hartford Empire Company in 1937, marking the birth of commercial blowing. While glass was initially used, it was soon replaced by plastic due to its fragility. Today, companies like Yamaha continue to use blow moulding to craft their fuel tanks, ensuring safety and an appealing exterior appearance.
The handmade nature of motorcycle fuel tanks allows for customization and attention to detail. Craftsmen play a crucial role in ensuring quality and eliminating deformations that may occur during the manufacturing process. Their proficient handwork and dynamic movements over the workpiece are a testament to their craftsmanship. Additionally, the exterior finish of the tank undergoes multiple inspections, including tactile checks and Polinet cloth polishing, to identify and rectify any imperfections.
In contrast, mass-produced fuel tanks are often associated with cost efficiency and safety standards. Companies like Röchling offer mass production services, ensuring that their tanks meet requirements for cold impact strength and hydrocarbon emissions. Mass production allows for the integration of additional functions, such as mounting devices and fuel pump interfaces, enhancing the attractiveness and functionality of the tanks.
While handmade tanks offer uniqueness and craftsmanship, mass production provides consistency and standardized safety features. The choice between handmade and mass-produced fuel tanks ultimately depends on factors such as cost, availability, and the desired level of customization and craftsmanship.
It is worth noting that the materials used for handmade and mass-produced fuel tanks may vary. Steel, aluminium, and plastic are commonly used materials, each offering unique advantages and disadvantages in terms of cost, weight, ease of welding, and resistance to corrosion and rust.
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Cost implications
The choice of materials for motorcycle fuel tanks involves several factors, including cost. Steel is the most commonly used material for motorcycle fuel tanks due to its low cost and ease of fabrication. It is cheap, easy to machine, and weld, making it a popular choice for manufacturers. However, steel is prone to rusting, which can be a concern for motorcycle owners, especially if the tank is not used frequently.
On the other hand, aluminium is a more expensive option and is harder to work with. It is lighter than steel but requires specialised equipment for welding, increasing the manufacturing costs. While aluminium is highly resistant to rust, it does corrode in the presence of salt and alkaline dust, requiring additional painting or treatment. Despite its advantages, aluminium's higher cost makes it less appealing to manufacturers, especially for mass-produced motorcycles.
Plastic is another alternative material for motorcycle fuel tanks. While plastic tanks are commonly used in dirt bikes, they have been associated with issues when used with certain types of fuel, such as ethanol-treated fuel. In these cases, the tanks can expand and contract, leading to deformation and safety concerns. Additionally, plastic tanks are more likely to rupture during a crash, potentially releasing fuel and increasing the risk of combustion. Despite these drawbacks, plastic remains an option for manufacturers due to its low cost, although it may not be suitable for all motorcycles or fuel types.
Stainless steel is another material that is known for its resistance to rust and corrosion. However, it is even more expensive than aluminium and challenging to fabricate. As a result, stainless steel fuel tanks are rarely used in motorcycles, as manufacturers prioritise cost-effectiveness and ease of production.
Ultimately, the cost implications play a significant role in the choice of materials for motorcycle fuel tanks. Manufacturers aim to balance factors such as durability, safety, and aesthetics while maintaining a competitive price point. Steel, with its low cost and ease of fabrication, remains the predominant choice, while aluminium and plastic are more commonly found in higher-end or specialised motorcycles.
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Safety considerations
Safety is the first priority when constructing motorcycle fuel tanks, given that the fuel they hold is highly flammable and volatile.
Motorcycle fuel tanks are typically made from steel, which is cheap and easy to work with. However, steel is susceptible to rust, which can cause fuel system contamination. Rusty fuel tanks can be dangerous, especially if the motorcycle is not used regularly, as the fuel and fumes may not be enough to keep the tank rust-free. While stainless steel is more resistant to rust, it is expensive and difficult to fabricate with, making it a less viable option for manufacturers.
Aluminum is another material that is used for motorcycle fuel tanks, particularly for higher-end bikes. Aluminum is lightweight and easy to machine and hammer, but it is also expensive and challenging to weld. Additionally, aluminum corrodes in the presence of salt and alkaline dust, so it needs to be painted, similar to steel.
Plastic fuel tanks are also available, but they come with their own set of safety concerns. Plastic tanks can be susceptible to heat deformation, causing the tanks to expand and contract, especially when used with ethanol-treated fuel. In the event of a crash, plastic tanks are more likely to rupture, releasing fuel that could potentially combust.
To ensure safety, it is crucial to consider the material used for the fuel tank, its thickness, and the construction process. Welding is a common method for joining the tank together, and minimizing the number of welds can simplify the process. Additionally, the shape and style of the tank must be carefully designed to match the bike's design lines and meet the required capacity.
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Frequently asked questions
Motorcycle fuel tanks are typically made from steel, although some are made from aluminium or plastic.
Steel is cheap and easy to work with, and tanks made from this material are safe and stylish.
Aluminium is more expensive than steel and harder to work with. It's also a burden for welders as it requires a specialised alternating current electrode.
Yes, aluminium is 2.5 times lighter than steel and highly resistant to rust.
Plastic tanks can be dangerous as they are more likely to rupture and release fuel in the event of a crash. They can also be damaged by heat and fuel, which can cause them to expand and contract.
