Fuel Tank Modification

Hi,

Following on from another thread, I am going to experiment with modifying a fuel tank.
I need at least 6 litres extra. This will give me a range of 300+kms.
Currently the fuel light comes on at 210kms.
So, I have a used tank on the way from the States.
I expect that cutting it round the widest part, above the frame rail is the best, and it needs to be raised somewhere between 1 ½ and 2” (38 – 50mm+).
Also, the fuel filler may need to be repositioned due to the angle it ends up at.
What I need from you artistic types is some sketches based on the premise above.
I usually use a tank bag, and will have to get a smaller one, if I raise the tank height.

Anyway Sketch away, show me you designs, the winning design gets a chocolate fish

Watch this space. I have just 3D scanned a GRiSO tank. I'll play with the design over the next month or two. Just out of interest does anyone on this list have Auto Cad .dwg or .rvt modelling experience? The aim is to build a tank with increased capacity that can then be 3d printed from the file I build.
Unfortunately I have just left work so I no longer have the toys to play with. On the flipside I'm now funemployed so should have the time to sort it out.

Awesome, I have AutoCad electrical at work but not 3D.

Darrell, avail yourself of several packages:
- DraftSight is an AutoCAD 1:1 replacement, and free, but is a 2D package;
- DesignSpark Mechanical is a full 3D package, again free, and you can generate 3D printing files directly from it;

The only "catch" is you have to re-register every 6 months. A small imposition...

It would be tricky to raise the tank without destroying the slick look of the GRiSO but could be done in my opinion.
You said you need about 6 more liters in capacity...it translates to me as a gallon and the half roughly, so that let me think that you'd have to raise the tank by probably more than an inch like you said. I could be wrong since I'm just eye balling this in my mind...

I've looked into this by making one from scratch in metal with an extra 1 US gallon capacity (3.8 liters).
There is at least half a gallon to be gained below the frame area while the rest would be up top.
The "raise" would need to be sloped inwards at the outside edges in order to flow with the look, instead of straight up, which would look like arse.
I just don't have enough time at the moment to custom fabricate a metal tank but it's still in my things to do for this bike.
While in the Carolina Mountains on a few occasions, I had to shorten my routes according to the smallish capacity of the bike's tank because gas station are scarce where I ride...so an extra gallon would allow me to ride all day into wilderness from 7am to 6pm anywhere in the area with only one stop at lunch time to eat and refuel and be back to base by day's end. I'm hard core I know.

Sorry, I can't draw or sketch for crap so I ain't going there...

Lastly, I don't know of any product on the market that would allow fusing successfully an "extension" to our plastic tanks.
Look into that before getting your hopes too high.

It would be awesome to be able to 3D print a larger tank in the correct fuel resistant plastic. I was involved in the early days of CNC machining with basic CAD/CAM software, the latest technology blows my mind.

Following this topic with interest. I like to do long tours and the low fuel capacity is definitely a small hindrance especially when you are as absent minded as me and happily ride past well-advertised fuelstations without noticing them

For a 3D software program look into Fusion 360.

Going through the AutoCad website forms, if you tick the boxes that say you are a student or will not be using it for commercial purposes, can't remember which. You can get the program for free.

I am hoping to follow some of the Youtube tutorials this winter break & get started learning this program, otherwise I'd have offered to help out.

Street, you're the Photoshop master, any photo suggestions for what this might look like ?

motor-timothy wrote:

Following this topic with interest. I like to do long tours and the low fuel capacity is definitely a small hindrance especially when you are as absent minded as me and happily ride past well-advertised  fuelstations without noticing them

Anyone who needs longer legs on a GRiSO is obviously younger than I am or has steel-lined bladder, or both!

I am quite ready to do bladder maintenance, grab some water or coffee, and annoy gas-station attendants with tales of yore by the time the yellow light comes on.

Bill

I couldn't agree more Bill.

Did You ever think of installing an Ipothesys Aria V12 tank? Could fit plug and pray....

Nobleswood wrote:

Street, you're the Photoshop master, any photo suggestions for what this might look like ?

Thanks for the compliment, but I'm afraid I wouldn't even know where to start with this one. I'm with Bill, ready to pee and stretch my legs every couple of hours so not too worried about getting more mileage. I put 50k on my GRiSO Rosso so very happy with it as a tourer. Granted, there have been a few times when I cut it a little close, but remodeling the tank seems pretty extreme to me. I'd prefer to carry a small amount of extra fuel, or maybe ride a different bike.

Pete

Street wrote:

Nobleswood wrote:

Street, you're the Photoshop master, any photo suggestions for what this might look like ?

Thanks for the compliment, but I'm afraid I wouldn't even know where to start with this one. I'm with Bill, ready to pee and stretch my legs every couple of hours so not too worried about getting more mileage. I put 50k on my GRiSO Rosso so very happy with it as a tourer. Granted, there have been a few times when I cut it a little close, but remodeling the tank seems pretty extreme to me. I'd prefer to carry a small amount of extra fuel, or maybe ride a different bike.

Pete

Me too, I've often thought a bit more range would be good and considered crafting a vinyl ester Glass or carbon tank, but then I saw a pretty Fat GRiSO with a 32 litre tank

I'm missing the point. Why not just buy a Stelvio NTX if you want a larger tank.

I'm happy with the range on my GRiSO.

My 2006 2V gets about the same around town 220 and light is on.
Open road 300km light on, I have a 4ltr fuel bag if needed.
Maybe a cheaper option, try Ballards off road.

There's a lot of good points of view here.
My reason for a bigger tank is this;
I like to do long distance rides, there is usually a time limit, so less fuel stops the better.
Should I get another bike, I won't trade in the GRiSO.
Also, a second bike means twice rego and insurance another $1200 per year,
I want to ride my GRiSO, can't do that while riding something else?
I've seen external fuel tanks, mounted behind the back wheel, or on the pillion seat, they don't look the part. It still needs to look like a GRiSO.
I ride with my brother usually, he is on a KTM adventure that gets 450km to a tank, I need to get to a minimum of 300kms, at a reasonable pace, to maintain the riding partnership. Anyway, I have just found a box of Kronenbourg 1664 that I am working my way through

Here ya go.
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Hmm, wonder why they didn't show both their faces. I also wonder how well it ran on cold water!

2highlander wrote:

Did You ever think of installing an Ipothesys Aria V12 tank? Could fit plug and pray....

Just looked at their website, looks like they may be able to help

Stubbie wrote:

Here ya go.
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I thought about it, might be good help shape the top of the tank, for a mould

So, here it is the blank canvas.
First impressions;
there are two drain tubes from around the filler to the back of the tank, getting these extended could be a job in itself
The plastic is quite thick, so plastic welding will be easier
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I saw someone the other day that had made a fiberglass tank and just sealed it with some POR paint for the inside of steel tanks. Not shure though how successful it was.

Surely finding/fabricating a mounting point suitable for 1 or 1.5 gallon Rotopax or Fuelpax for the occasional touring jaunt is a better option than fiddling with fine Italian lines...

Get creative...

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I'm willing to look at all options,
did some rides with a ZX10 and S1000, also small tanks, so I wasn't the only one needing to stop frequently

I am thinking about mounting a rotopax 2 gallon tank to the back where I have a givi rack attached.

I can go 130 miles before I need to find a gas station, and I am ready to stop and stretch by then. The problem with the 130 range isn't me, but I like to ride the Blue Ridge Parkway when I head north and I find that gas stations are few and far between and I don't want to run out of fuel nor do I want to have to ride 20 miles into a town and back. I wish they had put the tank capacity for the 1200 sport on the GRiSO.

I am headed to a COG rally in Pennsylvania in July and want to ride most of the BRP north and the range concerns me