Yamaha YBR-125
Moto Blog
Part 6 Yamaha YBR 125 - Homemade fiberglass fuel tank
Yamaha YBR-125
Yamaha YBR-125
1 month ago

Part 6 Yamaha YBR 125 - Homemade fiberglass fuel tank

It is a pleasure to welcome you again, dear reader!

This is already our 6th meeting within the Sandy project. Today I will try to fully describe the process of making a fiberglass fuel tank for a scrambler in an ordinary garage: from design to surface finish.

At the moment we have a concept of the tank and a photoshop drawing - and we start to begin.

The first thing I did was the neck. On ebay I bought a Chinese aluminum cap with a valve and threads (standard solution for pitbikes and their PP tanks). Using the lid itself, plastic and aluminum tape, I made a mold out of all this, pouring polyester resin inside it and shoving pieces of glass mat - I got almost a finished part! The only thing left is to twist off the slightly sticking lid and trim some places with a file:

Next, I created paper templates based on my drawing: longitudinal section and tank width calculation based on ergonomic requirements and style of our scrambler. I also created a couple of molds of the layer-by-layer cross-section of the tank from top to bottom, and transferred it all to fiberboard. I cut out the blanks of the future model with an electric jigsaw and glued this "skeleton" from them:

Now build up on the skeleton "meat" - fill the voids with insulation foam (because it is quite dense and easy to handle) and construction foam:

At this stage we again involve design thinking to finalize the shape of the future tank, and finally coat the resulting model with epoxy putty on plastic:

Now, so that the model does not fall apart during use, we reinforce it with a layer of epoxy, and we can make the matrix. But first we need to decide how to take this matrix apart and where to make the flanging:

So, the connector locations are marked with a marker taking into account the shape of the model - as you can see, there are only 4 components of the connector matrix. It was decided to use aluminum tape to make the flanges:

Next - I applied gelcoat and put a couple of layers of polyester mat on top - all this glued together perfectly. After the resin crystallization - drill holes in the flange and bolt the edges of the resulting "dumpling":

Unwind everything and take the matrix apart, there they are our 4 components:

I'll do the second part a little later. I can't insert more images :D

0 280
No CommentsNo Comments yet. You can write the first
Please Log In or install the app. Comments can be posted only by registered users.
Sign In
Content creation
See More