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Old 03-09-2009, 06:29 AM   #16
JohnTM
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Location: Cornersville, TN
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Quote:
Originally Posted by kubiak
the next pic is the same bike in dirt form with a bigger 6 gallon tank i made and 17x4.25 rear wheel and knobby.
OK, how the heck do you make a plastic fuel tank? I need one... (or is that metal?)
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Old 03-09-2009, 07:01 AM   #17
fritzcoinc
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Location: Cypress, Tx
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Home made racks for boxes on my Honda XR650L. Bent aluminum 1/2" solid bar and some Milwaukee saws all boxes. Total investment $18. The yellow reflector is courtesy of Tx. Dept. of Trans. ( bridge rail marker )

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Old 03-09-2009, 07:24 AM   #18
GSWayne
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Quote:
Originally Posted by rtortore
OK how did you manage to cut the plextglass/lexan? I am having huge problems with cracking/splitting as I cut it ... I thought of sandwiching it between two peices of wood - and cut the whole thing - but haven't tried it yet.

Cheers
Richard
Like Kevin said a bandsaw works well, that is what I used. I think a jigsaw will be OK if you can run it slow enough to prevent melting. The problem with the jigsaw is all the heat concentrated on one inch of blade. I think any ragged edges will just be on the top with a jigsaw. You might reduce the problem with a foot with a slot just big enough for the blade. A sharp fine blade with slower feed might also make for a cleaner edge.
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Old 03-09-2009, 09:13 AM   #19
fritzcoinc
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Quote:
Originally Posted by GSWayne
Like Kevin said a bandsaw works well, that is what I used. I think a jigsaw will be OK if you can run it slow enough to prevent melting. The problem with the jigsaw is all the heat concentrated on one inch of blade. I think any ragged edges will just be on the top with a jigsaw. You might reduce the problem with a foot with a slot just big enough for the blade. A sharp fine blade with slower feed might also make for a cleaner edge.
Before I got a good band saw I would clamp my jig saw balde up in my vice. Then you can move the material not the saw. For plastic you will need to experment with blades and not let the material get too hot. A smooth saw cut edge on Lexan can be smoothed with heat from a high BTU blow gun or carefull heating with a propane torch. To learn this experment on scrap pcs. first.
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Old 03-09-2009, 11:59 AM   #20
kubiak
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Quote:
Originally Posted by JohnTM
OK, how the heck do you make a plastic fuel tank? I need one... (or is that metal?)
i used the stock xrl steel tank then welded wings on it to hold fuel.stock holds 2.8 and with the fuel wings it holds 6.2 gallons.i first made a 4 gallon then a 4.5 gallon then last made the 6.2 gallon.i added some angular styling to it so it doesnt look too huge.

kubiak screwed with this post 12-02-2010 at 09:51 PM
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Old 03-09-2009, 12:01 PM   #21
kubiak
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Quote:
Originally Posted by kubiak
i used the stock xrl steel tank then welded wings on it to hold fuel.stock holds 2.8 and with the fuel wings it holds 6.2 gallons.i first made a 4 gallon then a 4.5 gallon then last made the 6.2 gallon.i added some angular styling to it so it doesnt look too huge.
heres the first paint job i did to it,noe i changed it a little by adding white to the bottom.

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Old 03-09-2009, 12:04 PM   #22
30Bones
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My KLR roots. Rear brake riser....Unsure where the Corona cap came from it's far too spendy for me



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Old 03-09-2009, 12:30 PM   #23
jehu
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Quote:
Originally Posted by kubiak
the next pic is the same bike in dirt form with a bigger 6 gallon tank i made and 17x4.25 rear wheel and knobby.
I never get tired of looking at your bikes kubiak. I first saw them a few years back on SMJ but rarely visit that site now. Glad to see you've made the switch also.
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Old 03-09-2009, 12:35 PM   #24
swingset
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Quote:
Originally Posted by rtortore
OK how did you manage to cut the plextglass/lexan? I am having huge problems with cracking/splitting as I cut it ... I thought of sandwiching it between two peices of wood - and cut the whole thing - but haven't tried it yet.

Cheers
Richard
If you're cracking it your using too-coarse of a cutter. Try a finer tooth, and play with the speed of the saw if it's adjustable. I can cut plexi & lexan with a normal old Makita jig-saw, if I have a fine blade.

Supporting the area immediately around the cut is also crucial, you often are well-served to make a jig or a base out of wood that you can cut and manuever the lexan on.
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Old 03-09-2009, 12:40 PM   #25
jehu
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My 304SS XR650R subframe extension and Summers rack support:
[IMG][/IMG]
[IMG][/IMG]
[IMG][/IMG]
[IMG][/IMG]
[IMG][/IMG]
Baja tested twice w/o problems
[IMG][/IMG]
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Old 03-09-2009, 01:02 PM   #26
fritzcoinc
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Quote:
Originally Posted by jehu
My 304SS XR650R subframe extension and Summers rack support:

Baja tested twice w/o problems
[IMG][/IMG]
Excelent work, looks great and hell for stout!
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Old 03-09-2009, 04:52 PM   #27
Ola M
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Quote:
Originally Posted by rtortore
OK how did you manage to cut the plextglass/lexan? I am having huge problems with cracking/splitting as I cut it ... I thought of sandwiching it between two peices of wood - and cut the whole thing - but haven't tried it yet.

Cheers
Richard
Are you trying in a cold shop? It's a lot easier if it's nice and toasty. The homemade aircraft builders know about this, they have to cut a $$$$ canopy to shape. This guy's excellent website details it: http://www.romeolima.com/RV8/Canopy.htm

70 deg F and a pneumatic cutting disc.
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Old 03-09-2009, 05:13 PM   #28
RoyB
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Moto Office


Custom Lexan Windscreens


A way to keep gunk out of the seat lock on the V-Strom.....plus Flip down license plate


GPS Mount

Lots more here:

http://public.fotki.com/Rbertalotto/...ycle-projects/
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Old 03-09-2009, 06:45 PM   #29
WIsixfitty
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lotsa cool stuff in here.


low exhaust, storage tube with rear view of skid/bash plate.



panniers fit to use all space available.
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Old 03-09-2009, 07:59 PM   #30
Louv
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Quote:
Originally Posted by rtortore
OK how did you manage to cut the plextglass/lexan? I am having huge problems with cracking/splitting as I cut it ... I thought of sandwiching it between two peices of wood - and cut the whole thing - but haven't tried it yet.

Cheers
Richard
Here's a great source of info on working with Acrylic (plexiglas):

http://www.tapplastics.com/info/acrylic.php?

Open the .pdfs for info on what kind of saw blades, cooling, polishing, etc.
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