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Old 03-16-2009, 05:51 PM   #1
Gustavo.Ramos OP
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640 Adventure tank and fairing?

need a little help here!

i'm in the middle of a bike project that involves the KTM adventure 28L tank and the old 620/640 adventure fairing, the one were we can remove/replace the screen.

somehow i've seen some of these tanks do not come fitted with the little pieces that bolt th tank together with the fairing.

How can this be solved? The tank is molded plastic, so no holes available, getting another tank is expensive.

Riding with this fairing without it being attached with the tank will rattle alot and brake sooner than later... any suggestions?

Pics:



thanks!
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Old 03-16-2009, 07:09 PM   #2
wrk2surf
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Maybe flat braces coming off the lower tank mount as a base?
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Old 03-16-2009, 09:36 PM   #3
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Maybe someone can plastic weld the mounts on there for ya? I hear folks who work with septic systems are good plastic welders. Info in the index on what type of plastic your tank is - that looks like PE at first glance.
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Old 03-17-2009, 02:13 AM   #4
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Did you get that tank from Afriquetom or Endurobunker on Ebay?

I would use some 25 or 30mm aluminum angle pieces, about 2mm thick and 4cm long. Glue these on the tank with epoxy (prepare it properly first, degreasing, sanding etc). Then get some industrial strength velcro and use that to stick the fairing to the brackets. This way you can still remove it fast and it shouldn't move. Another option is to use some Dzus fasteners.

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Old 03-17-2009, 03:20 AM   #5
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Gaffa tape works a treat....not very pretty though!!!
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Old 03-17-2009, 03:48 AM   #6
Gustavo.Ramos OP
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Quote:
Originally Posted by LukasM
Did you get that tank from Afriquetom or Endurobunker on Ebay?
Lukas, you are a twisted minded man

Quote:
Originally Posted by LukasM
I would use some 25 or 30mm aluminum angle pieces, about 2mm thick and 4cm long. Glue these on the tank with epoxy (prepare it properly first, degreasing, sanding etc). Then get some industrial strength velcro and use that to stick the fairing to the brackets. This way you can still remove it fast and it shouldn't move. Another option is to use some Dzus fasteners.

What i find weird is what bike is this tank suposed to be used

I'm more inclined to building some brackets that come from the inside lower tank mounts as wrk2surf mentioned.

Meanwhile i might get another tank... i feel my garage to be quite empty...
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Old 03-17-2009, 05:46 AM   #7
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Quote:
Originally Posted by Gustavo.Ramos
What i find weird is what bike is this tank suposed to be used
From old LC4 rallye?




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Old 03-17-2009, 06:07 AM   #8
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The tank from my picture above is actually a standard KTM 18L tank from the LC4-Enduro. It was modified by Griesser Motorsport as I described above in order to fit a rally fairing - the same thing Gustavo wants to do:




Griesser built a few of these combinations and used them to convert some EXCs to Rally bikes. I actually got the used yellow fairing from this bike:






I will be mating it to a Safari tank on my DR. Finally ordered the composite supplies so I hope to get this done before the summer. Then I'll go test it in Morocco.

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Old 03-17-2009, 09:04 AM   #9
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PE is one of the least glueable plastics but, with a Heat Treatment prep, epoxies will give excellent results.

The key to strong structural bonds with any epoxies on PE (HDPE & LDPE) is the ''Heat Treatment'' ...& not a specific type of epoxy.

See here:
http://www.tapplastics.com/info/vide...=windowsmedia&
''Heat treatment'' for good bonds & ''Patience'' for a good Howto! (takes a little while to download)
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Old 03-17-2009, 12:52 PM   #10
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Quote:
Originally Posted by K2ride
PE is one of the least glueable plastics but, with a Heat Treatment prep, epoxies will give excellent results.

The key to strong structural bonds with any epoxies on PE (HDPE & LDPE) is the ''Heat Treatment'' ...& not a specific type of epoxy.

See here:
http://www.tapplastics.com/info/vide...=windowsmedia&
''Heat treatment'' for good bonds & ''Patience'' for a good Howto! (takes a little while to download)
Interesting video! i wonder if it can be used to glue 4 small metal plates to the tank?

Or at least have these properly and permenantly boled to the tank
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Old 03-17-2009, 03:26 PM   #11
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Epoxies bond to almost anything if its bonding surface has been prep to do so.

The use of reinforcing material (fiberglass) to widen the bonding surface will fork out the desired structural integrity.

Simply put:
Bonding metal support fittings to the HDPE tank isn't a problem if the HDPE's bonding surface has been acetone cleaned & Heat treated.
As for the metal or aluminium supports, simply follow the recommended prep work specific to the material of your choice.

Btw,
There's a guy up here that epoxy bonded rough hand shaped aluminium protection plates (3 per side to allow some flexing of the tank) to his aftermarket HDPE Adv tank without any fiber reinforcement; they're stil in place after two years &, from the looks of them, we have no doupt that the tank as the rest of the bike flexed often!
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Old 03-17-2009, 07:45 PM   #12
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If you guys are going this far with tabs and adhesives I would just use some fiberglass and mat or epoxy like said eariler and just put the nut right on the tank just like an adventure 30ltr just a few mm's higher.. By the way I picked up a 30ltr here in great shape for 275 usd or so.
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Old 12-15-2010, 09:53 PM   #13
hot101rod
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Fairing and tank to the DR

How did it come out, any pictures? I have a pre 2002 adv tank and fairing I was thinking of putting on my DRZ400 in rally style. But not sure if it would be worth all the trouble. Suggestions?????
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Old 07-22-2011, 06:21 AM   #14
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Sorry man, didn't saw your post, neither finished the project the way it was planned:

here's how she is now:



cheers,
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