The "Tanker Brace"...XR650R/Acerbis Sahara Tank Brace and Radiator Guard

Hodakaguy · 02-21-2009, 08:53 PM

The "Tanker Brace" is a brace/guard designed for XR650R's that are running a Acerbis Sahara Desert Tank (Also works great with the Clark, IMS, and OEM tanks). (DRZ/IMS guards are in the works also). After installing a Sahara onto my XRR I found a few problems with the lower braces that are supplied with the tanks. I designed/built the Tanker Brace to solve these problems. After building one for myself a few other people wanted them so I decided to produce some for sale.

* First I found the Sahara tank will flex inward quite a bit when full, enough that it contacted/rubbed my radiator and KTM fan that I had installed. The Tanker Brace adds a small amount of pre-load (you pull the tank outward a bit to slide the brace in) that keeps the tank from rubbing the radiators/fan setups when full. Check the inside of your Sahara tank, you might find that yours has been rubbing the radiators also.

* I didn't feel that the provided Acerbis lower braces would provide enough protection for the radiators in a crash. The Sahara tank itself adds a good amount of radiator protection since it covers the sides of the radiators, but I've read where the tank can still flex enough to damage the radiators in a crash. The Tanker Brace ties both sides of the tank together and then into the upper motor mount that the Acerbis mounts used. Even if you crash hard enough to bend the Tanker Brace the extra space cushion between the tank and radiators provided by the pre-load of the Tanker Brace should keep the radiators damage free.

* I installed Unabiker radiator guards on my XRR. (This was the step that started the Tanker Brace build) After installing the guards I found that the Acerbis lower braces wouldn't fit any more with the Unabikers installed. The Tanker Brace allows the Unabikers to be used with the Sahara tank. (I believe the Sahara/Tanker Brace combo will protect the radiators sufficiently without need for extra radiator braces.....ie. Unabikers ect)

The Tanker Brace is fully TIG welded and parts are CNC cut. The braces come painted satin black with a fine textured finish . They are pre-threaded to accept the factory Acerbis hardware.

** Makes swapping between tanks a quick job as the tanks line up every time!, if you've dealt with the stock Acerbis lower brackets you know how flimsy they are and how they don't want to line up correctly.**

Cost: $55 + $10 shipping (Cont USA). PM me for payment details if you are interested in a brace.

Thanks.

Just out of the Jig.

Here's a shot of the Tanker Brace installed on my XRR. You can see how it attaches into the front engine bolt and both sides of the tank.

Side Shot

Left Side View

Hodakaguy

jesusgatos · 02-21-2009, 09:31 PM

Right on. Are the sheetmetal parts laser or water-jet cut, or hand-cut? Just wondering...

Hodakaguy · 02-21-2009, 09:48 PM

Quote:

Originally Posted by jesusgatos

Right on. Are the sheetmetal parts laser or water-jet cut, or hand-cut? Just wondering...

The whole assy is hand built. I built the first one and got it just where I want it, then I built a jig so I can replicate them the exact same each time. I made a couple other small jig/tools to get the cuts and bends in the flat bar ect.

Hodakaguy

jesusgatos · 02-22-2009, 12:11 AM

If you want to give me me some dimensions or drawings, I'll create some simple CAD drawings for you so that you can have those parts laser cut. You'd be able to put those braces together a lot quicker...

YnotJP? · 02-22-2009, 02:46 AM

For a short run of items, which this probably will be, my guess would be that the way you are doing it is the best, most cost affective way.

Good luck, it looks like that you have made a nice product for others to use.

I must say, I have followed your posts, and you seem to enjoy your XR650R, and riding it, and improving the BRP.

I see from some of you photos that you ride near Finley, across the river from Wallula.

Hodakaguy · 02-22-2009, 05:54 AM

Quote:

Originally Posted by YnotJP?

For a short run of items, which this probably will be, my guess would be that the way you are doing it is the best, most cost affective way.

Good luck, it looks like that you have made a nice product for others to use.

I must say, I have followed your posts, and you seem to enjoy your XR650R, and riding it, and improving the BRP.

I see from some of you photos that you ride near Finley, across the river from Wallula.

Yeah I figured that I would make a small batch of them and see how they sell, if they sell I'll make another small batch. I also figure it will be a limited market. Jesusgatos....Thanks for the offer, if I was doing a bunch of them I would defiantly take you up on your offer.

Yeah we ride out in hover quite a bit, just out past Fintucky.

You must have spent some time around here.

Hodakaguy

FOCKER · 02-22-2009, 08:55 PM

I gotta say that the build quality is the bomb! I got the first one and it fits like a glove. Only robotic laser cutting could produce something like this...In fact Hodakaguy might be a robot.

He is VERY meticulous regarding every cut, weld, grind and bend...Down to the cardboard thickness of the packaging!

You won't be disappointed...I'm not saying this to help boost his sales (He doesn't need the $) I'm saying this because he's a good guy and his talents deserve recognition.

~Focker

Stevevh · 02-24-2009, 12:27 PM

Just got done installing the brace. It took me about 20 minutes and I did not have to take anything off the bike. Pretty amazing build quality, better than a lot of the retail aftermarket stuff I have bought lately. Really appreciate you doing this build Tom! Great work!!!

Oh, also now my tank lines up with the bolt holes, unlike the crap bent ones that came with the tank. Makes getting the tank on that much easier!!!

X2 Hodakarobot is a very good guy,...uh robot!!

Hodakaguy · 02-27-2009, 04:51 AM

Quote:

Originally Posted by Stevevh

Just got done installing the brace. It took me about 20 minutes and I did not have to take anything off the bike. Pretty amazing build quality, better than a lot of the retail aftermarket stuff I have bought lately. Really appreciate you doing this build Tom! Great work!!!

Oh, also now my tank lines up with the bolt holes, unlike the crap bent ones that came with the tank. Makes getting the tank on that much easier!!!

X2 Hodakarobot is a very good guy,...uh robot!!

Glad to hear that it fit good, I have 5 left from this batch. If I run out and there is still demand I'll fab another batch of them.

Thanks for the post.

Hodakaguy

Hodakaguy · 03-26-2009, 03:55 PM

I just finished a second batch of the braces, I have 7 left as of now. If you would like one just PM me.

Thanks,

Hodakaguy

Stevevh · 03-26-2009, 06:27 PM

Just a quick update!

Just got back from a DS trip in OK and although I never crashed I did dump the BRP on the tank and the braces held up very well. Thanks again for doing this!

Hodakaguy · 03-30-2009, 08:03 PM

Quote:

Originally Posted by Stevevh

Just a quick update!

Just got back from a DS trip in OK and although I never crashed I did dump the BRP on the tank and the braces held up very well. Thanks again for doing this!

Hey Steve. Glad its working good for you. I feel it ads a bit of extra insurance.

Thanks for the follow up.

Hodakaguy

SuperBonBon · 04-17-2009, 10:01 PM

Just installed my new brace. Took less than 5 minutes to get on - a perfect fit! Way easier to get on than the original hardware.

My brace was shipped out the day after I ordered it, and arrived to me (in Canada!) 4 days later.

Thanks for a very good product - I hope it never gets tested.

Hodakaguy · 04-30-2009, 04:34 PM

Quote:

Originally Posted by SuperBonBon

Just installed my new brace. Took less than 5 minutes to get on - a perfect fit! Way easier to get on than the original hardware.

My brace was shipped out the day after I ordered it, and arrived to me (in Canada!) 4 days later.

Thanks for a very good product - I hope it never gets tested.

Glad you liked it

I just ran out of the braces but will be doing another batch soon. I'll have the DRZ/IMS braces finished up soon also (To many house projects going on now....Arggggg

)

Hodakaguy

Stevevh · 05-02-2009, 06:29 PM

Quote:

Originally Posted by SuperBonBon

Just installed my new brace. Took less than 5 minutes to get on - a perfect fit! Way easier to get on than the original hardware.

My brace was shipped out the day after I ordered it, and arrived to me (in Canada!) 4 days later.

Thanks for a very good product - I hope it never gets tested.

Test away!!!! I have dropped the XR a few times and the braces are holding up great. These along with the big Acerbis tank really protect the radiators very well. A great product!!!!

Here is a good picture of it installed on my piggy!

02-21-2009, 08:53 PM	#1
Hodakaguy ^OP NorthWest Adventure Rider Joined: Jul 2007 Location: Eastern WA State Oddometer: 1,681	The "Tanker Brace"...XR650R - Acerbis Sahara/Clark Tank Brace and Radiator Guard The "Tanker Brace" is a brace/guard designed for XR650R's that are running a Acerbis Sahara Desert Tank (Also works great with the Clark, IMS, and OEM tanks). (DRZ/IMS guards are in the works also). After installing a Sahara onto my XRR I found a few problems with the lower braces that are supplied with the tanks. I designed/built the Tanker Brace to solve these problems. After building one for myself a few other people wanted them so I decided to produce some for sale. * First I found the Sahara tank will flex inward quite a bit when full, enough that it contacted/rubbed my radiator and KTM fan that I had installed. The Tanker Brace adds a small amount of pre-load (you pull the tank outward a bit to slide the brace in) that keeps the tank from rubbing the radiators/fan setups when full. Check the inside of your Sahara tank, you might find that yours has been rubbing the radiators also. * I didn't feel that the provided Acerbis lower braces would provide enough protection for the radiators in a crash. The Sahara tank itself adds a good amount of radiator protection since it covers the sides of the radiators, but I've read where the tank can still flex enough to damage the radiators in a crash. The Tanker Brace ties both sides of the tank together and then into the upper motor mount that the Acerbis mounts used. Even if you crash hard enough to bend the Tanker Brace the extra space cushion between the tank and radiators provided by the pre-load of the Tanker Brace should keep the radiators damage free. * I installed Unabiker radiator guards on my XRR. (This was the step that started the Tanker Brace build) After installing the guards I found that the Acerbis lower braces wouldn't fit any more with the Unabikers installed. The Tanker Brace allows the Unabikers to be used with the Sahara tank. (I believe the Sahara/Tanker Brace combo will protect the radiators sufficiently without need for extra radiator braces.....ie. Unabikers ect) The Tanker Brace is fully TIG welded and parts are CNC cut. The braces come painted satin black with a fine textured finish . They are pre-threaded to accept the factory Acerbis hardware. Makes swapping between tanks a quick job as the tanks line up every time!, if you've dealt with the stock Acerbis lower brackets you know how flimsy they are and how they don't want to line up correctly. Cost: $55 + $10 shipping (Cont USA). PM me for payment details if you are interested in a brace. Thanks. Just out of the Jig. Here's a shot of the Tanker Brace installed on my XRR. You can see how it attaches into the front engine bolt and both sides of the tank. Side Shot Left Side View Hodakaguy __________________ NV 2012 - In Memory of the Crewmen RR: CLICK HERE Adventure Is Out There - NV RR: CLICK HERE Riding Through History - NV RR: CLICK HERE And Then There Were Four - OR RR: CLICK HERE My VW Syncro Westy Build Thread: CLICK HERE Hodakaguy screwed with this post 11-05-2011 at 05:58 AM

02-22-2009, 02:46 AM	#5
YnotJP? Beastly Adventurer Joined: Dec 2007 Location: Philippines and Seattle Oddometer: 1,626	Hodakaguy For a short run of items, which this probably will be, my guess would be that the way you are doing it is the best, most cost affective way. Good luck, it looks like that you have made a nice product for others to use. I must say, I have followed your posts, and you seem to enjoy your XR650R, and riding it, and improving the BRP. I see from some of you photos that you ride near Finley, across the river from Wallula.

02-22-2009, 08:55 PM	#7
FOCKER Northwest Adventure Rider Joined: Jan 2008 Location: Eastern WA Oddometer: 127	I gotta say that the build quality is the bomb! I got the first one and it fits like a glove. Only robotic laser cutting could produce something like this...In fact Hodakaguy might be a robot. He is VERY meticulous regarding every cut, weld, grind and bend...Down to the cardboard thickness of the packaging! You won't be disappointed...I'm not saying this to help boost his sales (He doesn't need the $) I'm saying this because he's a good guy and his talents deserve recognition. ~Focker __________________ Check out the XR650R Forum www.XR650RFORUM.com (Baldy said I could)

03-26-2009, 03:55 PM	#10
Hodakaguy ^OP NorthWest Adventure Rider Joined: Jul 2007 Location: Eastern WA State Oddometer: 1,681	I just finished a second batch of the braces, I have 7 left as of now. If you would like one just PM me. Thanks, Hodakaguy __________________ NV 2012 - In Memory of the Crewmen RR: CLICK HERE Adventure Is Out There - NV RR: CLICK HERE Riding Through History - NV RR: CLICK HERE And Then There Were Four - OR RR: CLICK HERE My VW Syncro Westy Build Thread: CLICK HERE

04-17-2009, 10:01 PM	#13
SuperBonBon Gnarly Adventurer Joined: May 2006 Location: Kelowna Oddometer: 144	Just installed my new brace. Took less than 5 minutes to get on - a perfect fit! Way easier to get on than the original hardware. My brace was shipped out the day after I ordered it, and arrived to me (in Canada!) 4 days later. Thanks for a very good product - I hope it never gets tested. __________________ Build a man a fire and he'll be warm for a day. Set a man on fire and he'll be hot for the rest of his life.

02-21-2009, 09:31 PM	#2
jesusgatos fishing with dynamite Joined: Nov 2006 Location: on the road Oddometer: 2,035	Right on. Are the sheetmetal parts laser or water-jet cut, or hand-cut? Just wondering...

02-22-2009, 12:11 AM	#4
jesusgatos fishing with dynamite Joined: Nov 2006 Location: on the road Oddometer: 2,035	If you want to give me me some dimensions or drawings, I'll create some simple CAD drawings for you so that you can have those parts laser cut. You'd be able to put those braces together a lot quicker...

02-24-2009, 12:27 PM	#8
Stevevh Kudu Driver Joined: Jul 2006 Location: Dallas/FtWorth TX Oddometer: 274	Just got done installing the brace. It took me about 20 minutes and I did not have to take anything off the bike. Pretty amazing build quality, better than a lot of the retail aftermarket stuff I have bought lately. Really appreciate you doing this build Tom! Great work!!! Oh, also now my tank lines up with the bolt holes, unlike the crap bent ones that came with the tank. Makes getting the tank on that much easier!!! X2 Hodakarobot is a very good guy,...uh robot!!

03-26-2009, 06:27 PM	#11
Stevevh Kudu Driver Joined: Jul 2006 Location: Dallas/FtWorth TX Oddometer: 274	Just a quick update! Just got back from a DS trip in OK and although I never crashed I did dump the BRP on the tank and the braces held up very well. Thanks again for doing this!

Thread Tools	Search this Thread
Show Printable Version Email this Page	Search this Thread: .
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode