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Old 05-08-2011, 05:14 PM   #1
AdvRonski OP
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Joined: Feb 2007
Location: Wishing I was back in Grand Junction, now in MN
Oddometer: 688
An Auxiliary Fuel Tank is Born

I have been thinking about adding an aux. fuel tank the the 950 ever since I converted to a 2-1 exhaust. The huge, empty space where the left muffler used to be beckoned to me, while I considered some options.
Convert the old muffler into a fuel tank-
This looked like a huge PITA to me. The only way to gut the muffler's baffles seemed to be cutting it in half length-wise, and it would barely hold 1 gallon of fuel. Nope.
Neduro's AdvTank looked promising, but availability was a problem, and I had some concerns about the rigidity of the mounts. There are a few reports of tanks rubbing on the rear tire when mounts bent. Plus, 400 bucks isn't easy to part with.
Make my own out of aluminum-
Now this I like. I can design it just how I want it, and make the mounting system plenty stout. Also, I just like the look of custom fabbed aluminum bits, like my skidplate and swingarm projects.

http://www.advrider.com/forums/showthread.php?t=657112

http://www.advrider.com/forums/showthread.php?t=640537

After some goofing around with different shapes, I came up with an elongated hexagonal cross-section,





The tank would impinge on the swingarm at full compression, so a cutout would be needed,





After some tweaking, the final shape emerges,



Note the high-tech rear wheel stand,



Since I don't have access to a large sheet-metal brake, I had a fuel tank company bend the basic shell out of .125 5052 aluminum alloy,



The cutout for the swingarm is fitted,



And checked for fit on the bike,





Before welding the shell halves together, I added a baffle in the center of the tank, to keep fuel slosh at a minimum under 950-style hard acceleration,





Then it was time to put it together, and start welding,



Starting to look like something!,



Now, for some mounts that will have to control the movement of a close-to-30 pound tank of gasoline. The top mount is easy enough, just use the muffler mount to hang it from. The front and rear mounts need to be as low as possible to control tank movement, while also isolating the tank from engine vibration. Since I don't plan on ever taking the stock KTM rear bag mounts off, they are the perfect spot to use as mounting points.
First, the front mount gets a bracket,



And a stainless-steel bracket joins the rubber-mounted left side crossover pipe mount with a small rubber mount on the new bracket,





The nose of the tank is narrowed to give frame clearance,



And a tab is added to mount to the bracket,



Some detail on the bottom plate, where the KTM fuel valve will mount,



The screws that fasten the fuel valve need to be sealed, or they will leak fuel. I considered different methods to accomplish this, and settled on just building up the areas above the screw holes with layers of welded material,



Wow, that is a lot of welding. But it looks good to me!,



Now, I need some way to put fuel in it. I'll start with a big hole,



Finding a fuel filler was a bit of a problem. There were huge fillers for diesel fuel tanks, and some very short fillers for drag racing tanks, but nothing really suitable for my purpose. I found an oil filler extension for VW buggy engines that seemed about right,





Unfortunately, the first time I screwed the finely-made aluminum cap on, it galled the threads, and I had to cut the damn thing off!,



Well, when you need some fancy machining done for a 950, who do you call?
That's right! You call Craig at CJ Designs, and beg for mercy!
What I really wanted, I explained, was a fuel filler tube that would fit a small KTM fuel cap. Would you PLEASE consider making one before you go off to Alaska for the summer?
Incredibly, he was just going to make a few up for his own fuel tank project, so it would be no big deal to make one for me! No freaking way!
Thanks Again Craig!!!

So, while I marveled at my good fortune, I finished the rear tank mount by adding a mounting block on the rear of the tank. Then I welded another bracket on the bag mount cross-bar, and joined the two with a stainless-steel bracket that bolted to the tank through rubber mounts,



In a few days, the filler arrived from Craig, and I welded it into place.
The finished tank looks great, and holds about 2.4 gallons of fuel, good for around an extra 100 miles or so,





Thanks to Craig at CJ Designs, and also Ned at AdvTank, who very kindly donated a fuel check valve to this project, although he had no idea what I was up to with it.
Thanks, Guys!
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Old 05-08-2011, 05:20 PM   #2
Deadly99
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Very nice
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Old 05-08-2011, 05:41 PM   #3
viola-tor
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Nice work! I particularly like the FMF sticker. The baffle is clever!

I'm so jealous of you guys with welding tools and knowledge to operate them. I may have to do something about that in my workshop...
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Old 05-08-2011, 05:42 PM   #4
aurel
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Nice job
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Old 05-08-2011, 05:53 PM   #5
Dusty
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Sweet!
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Old 05-08-2011, 05:56 PM   #6
bikyto
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very nice! Looks awesome
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Old 05-08-2011, 06:05 PM   #7
WIsixfitty
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cheers to the do it yourselfers.
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Old 05-08-2011, 06:05 PM   #8
RickS
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Looks great! Am I missing something here, but should there not be a hole at the bottom of the baffle as it appears that some fuel will not be avaiable due to the lower hole being a inch of so off the bottom? It may just be the angle of the photo - if so sorry.
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Old 05-08-2011, 06:25 PM   #9
rocker59
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Quote:
Originally Posted by RickS View Post
Looks great! Am I missing something here, but should there not be a hole at the bottom of the baffle as it appears that some fuel will not be avaiable due to the lower hole being a inch of so off the bottom? It may just be the angle of the photo - if so sorry.
Take a closer look.
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Old 05-08-2011, 06:25 PM   #10
dejr2000
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There is a small opening between bottom of tank and the baffle, baffle doesn't go all the way to bottom of tank.
Great project! Thanks for sharing
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Old 05-08-2011, 06:46 PM   #11
rocker59
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Yep. Great project!
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Old 05-08-2011, 07:25 PM   #12
JTXT
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Nice work!!!
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Old 05-08-2011, 07:47 PM   #13
wheatwhacker
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Great work.
How many gallons?
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Old 05-08-2011, 08:09 PM   #14
RickS
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Quote:
Originally Posted by dejr2000 View Post
There is a small opening between bottom of tank and the baffle, baffle doesn't go all the way to bottom of tank.
Great project! Thanks for sharing
See that now. excellent project and great looking!!!!!!!!!!
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Old 05-08-2011, 08:44 PM   #15
DakarNick
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Originally Posted by viola-tor View Post
Nice work! I particularly like the FMF sticker. The baffle is clever!

I'm so jealous of you guys with welding tools and knowledge to operate them. I may have to do something about that in my workshop...
I'm with you there! I can fabricate but don't have a brake or a tig! Yes, nice work!
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