Honda VFR 750 XC Makeover

[PhiSig1071]

Looking forward to following your progress.

[Quacamole]

Originally Posted by sailah

With your fab skills, I'd seriously consider a tank from scratch. I've fought with modifying tanks before and usually the result is less than stellar.

You also could consider redoing the subframe and putting a couple gallons there by replacing the entire thing and plating in some tubes. I tried this on my last build and got 2.16 gallons under there. I'm thinking about making a new one with 4 gallons as it's my only tank.

You could make a slim tank on top with 4-5 gallons and get 3 under the seat.

To make it from scratch I dont have any sheetmetal treatment machinery available, so it will be quite angular. Easier to modify some existing tank I think. Also was thinking to shove all the electrics inside the subframe, and use 950 plastics over there. BMW F800 has nice set up for a tank, but that's where my silencers will be.
Your CBR has only 2.16 gallon tank - was wondering will you add something on top of the engine like your FZ1 has?

[Quacamole]

Originally Posted by TerraRoot

I thought the point of use the ktm as the start point was to bolt on the ktm bits after the engine was in?

That was one of the ideas, but hard to get these tanks and they'r expensive + KTM original frame is with straight tubes, mine has an angle so the KTM tanks will be looking outwars like wings.

[sailah]

Originally Posted by Quacamole

To make it from scratch I dont have any sheetmetal treatment machinery available, so it will be quite angular. Easier to modify some existing tank I think. Also was thinking to shove all the electrics inside the subframe, and use 950 plastics over there. BMW F800 has nice set up for a tank, but that's where my silencers will be.
Your CBR has only 2.16 gallon tank - was wondering will you add something on top of the engine like your FZ1 has?

The cbr is just a toy so no top tank. Thinking about building another tank with 3-4 gals though.

Tanks are tough to get to look right, they are so visible and in many cases, the focal point of the bike. I had to cut the fz1 tank but not that much and it was a lot of work. Plan on lining the tank when you are done I had a few pinholes from welding that were impossible to get with a tig torch.

That gs tank just looks huge. I wonder if there is a smaller main tank that would fit the frame better and maybe a side pipe tank or subframe tank to get you the volume you want?

[Keith]

Supposedly one can fill and cap thinwall pipes with sand to keep them from wrinkling like that.

[KaceCoyote]

A split tank may be a better idea. I carry the fuel lower and so fourth, and you dont have to worry quite so much about the width in question.I worry about the bar clearance.

[snowhawk jockey]

Cutting the Tank into thirds:
Each side and the center span.
Replacing the center span with flat sheet metal, increasing the width, until sides are in acceptable position for the frame.

[Quacamole]

Thanks for the good advice and ides for all of you. Have been working in Sweden for two weeks, will be back next week to continue with the bike.

About the tank - looks like I'll be cutting it in three sectoins as snowhawk jockey suggested, but I have to take look
at it again when I'm back.

Br.,

[SloMo228]

I love builds like this. Subscribed!

[Quacamole]

Back in the workshop, but I only had couple of hours for some serious engineering and designing.
Decided not to cut the tank into three pieces, instead I cut the areas off from lower side to make the
tank fit. Probably will cut the whole lower side off and weld VFR tank's lower side to it.



Also cut the VFR tank into half - lot of sludge inside



Lower side of it, which I'm thinking to use



VFR gas cap fits the GS tank opening but to lock it some mods are needed



So the result should be something like below







Area where the additional tank volume will be added

[Quacamole]

Also KTM SM silencers arrived while I was away. Heavy bastards, thought them to be lighter like everything else
on KTM's. Maybe I'll end up using only one - still thinking

[SloMo228]

Very cool. Did you take any kind of precautions with regard to gas fumes before cutting the tank? I have been thinking of cutting off the bottom of my bike's tank to attach a larger-capacity top to it since the stock tank has odd dimensions and few tanks I've seen are close, but I worry about accidentally setting off an explosion in my face.

[Quacamole]

Originally Posted by SloMo228

Very cool. Did you take any kind of precautions with regard to gas fumes before cutting the tank? I have been thinking of cutting off the bottom of my bike's tank to attach a larger-capacity top to it since the stock tank has odd dimensions and few tanks I've seen are close, but I worry about accidentally setting off an explosion in my face.

Just flushed the tank with high pressure water couple of times and left the water inside, while using angle gringer.
Can also use the jig saw or recip saw not to create the sparks.

[R1100purist]

This is the coolest thread I have seen in awhile! Keep it up.

[mikejohn]

Originally Posted by Quacamole

Also KTM SM silencers arrived while I was away. Heavy bastards, thought them to be lighter like everything else
on KTM's. Maybe I'll end up using only one - still thinking

De-cat them, might save some weight there