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In order to make the new tanks as good as they can possibly be, we need to find the best tank that we have from which we can take a mould.

The attributes of a good tank are:

• * That it has not swollen / distorted due to ethanol
  * That it has a good surface finish

I doubt we have access to one that fully meets these attributes but we need to find the best we have.

I have a spare tank that has been empty and unused for about five and a half years - and until we find a better one, I guess that is our primary candidate.

I will appeal for one on the main forum - if someone thinks they might want a carbon tank at some point in the future, they may be willing to help us get the mould made.

If anyone else has one or has a lead to where we might find one, then please post up.

I've got a spare one that's been empty for yonks and although it's painted a questionable colour the finish appears good.

It's a long way away though and will be going into storage in a month so speak sooner rather than later.

Cheers Dale - appreciated.

Not sure how we can easily compare yours with mine (or others that may turn up) but it's good to have that as an alternative.

I think that one thing that we need to try with any of these "candidate tanks" is how well they fit on the bikes.

I'll try to find time to fit mine - I guess you doing the same depends on how feasible it is to do one handed .... or at least with one arm in plaster!

I have the donor bike on the stand that I should be able to try it without too much trouble, even partially disabled. I'll let you know.

Thanks Dale

Keep on backup-standby for the moment. It seems that Richard may have access to some good tanks himself.

I may have a couple of options for the pattern tank. If I can get a good used one that is one option. It needs to be a good surface finish with no stickers, scratches or obvious marks. The better the tank the better the mould and the sooner it can be used once it has been made. I have spent 3 or 4 days wet sanding a mould to get a good surface when the pattern was not quite a good as promised. It also makes it quicker to get it moulded as obvious issues need to be sorted before it is moulded. So spraying with a resin based primer and top coat add time and cost. Time is the biggest one as it can add a couple of days or a week before the mould can be started. Nooj may have access to a brand new tank too.

I did drag my spare tank out today ..... and it is a bit rough.

The OEM stickers are still on there - one of them coming away.
There are some scratches etc ... so it's not ideal.

I removed the fuel pump to have a look at that assembly and also the filler cap.

I've never had one of these tanks open before. The overflow/drain pipes from the filler cap area to the tank base were quite an interesting feature.

Fuel Pump Assembly:


The Drain/Overflow pipes inside the tank (viewed from the hole where the fuel-pump sits):


Anyway Richard, although I don't think my spare tank is going to be our first choice for mould making, you are welcome to have it to take to the mould maker so that he can get the general idea.
Please let me know if you want it and if so, where and when would be good to drop it off with you.

Brilliant.. I didnt use the drain option on mine as there was no way to actually put a pipe into the tank and bond on the base.. But this may be easier as access would be easier with the large fuel pump opening being there... We will have to meet up later this week so I can take the tank up to the mould makers....

I've bought a brand new tank for this, so there will be no problems associated with ethanol swelling

Top work, Nooj...