Aluminium fuel tank for motorcycle

[daveh]

Having made a steel fuel tank for my 1974 Norton Commando I wanted do one from aluminium of a similar style that holds more than the 11 litre standard roadster tank.

I am using 2mm (0.80”) 1100-H-14 and started by marking the base of the standard tank onto a board then widened the front section to give the extra volume. The wireframe buck was then built onto this board.

I mostly used 4mm (0.160”) steel rod for the wireform and pretty well the minimum number of pieces to get the shape I wanted. It was easily bent using a couple of fork ended flat bars and TIG welded together. Once complete the baseboard was removed.

Below the forks used to bend the 4mm steel rod.




Photo below shows how sections were held in place for welding


The finished wireform is quite rigid and light and has good visibility as the panels are made. I prefer them to a wooden buck.

To be continued.

[cliffrod]

Great to see some Norton-bound work happening here, Dave. I'm very interested and will be watching.

[skintkarter]

Look forward to watching your progress here Dave. I did an Imola style tank for a Ducati trellis frame last year. Lots of work making it avoid all of the gubbins underneath. Finished up at 21 litres

Cheers, Richard

[RockHillWill]

Very nice buck work. Keep posting your progress.

[daveh]

When I made the steel tank it took longer to do the tunnel and underneath than to do the outer surface as it is a complex shape to miss frame tubes and other stuff. But I started this with the outer shape as that’s the fun part. I started with the front RH curved side and due to the thick aluminium being quite stiff I annealed it which allowed it to quickly take shape on the stump, before smoothing on the wheel. The rear of this panel has a flange turned to allow the rear side section to be butt welded. Because I had to move this turned flange a couple of times it ended up badly marked which would be a potential for a crack, so I ran a bead of weld on the inside corner after I had done the butt weld. The outer panels will be gas welded. Please excuse the mess, I work in a 12 foot X 8 foot shed so it is all piled in.

Here is the front section on the wireform, The rear section was also clamped on for welding




Below shows the bead run into the much abused corner of the flange.



Below the outer weld bead before dressing. I use a dremmel and carbide bit to remove the highs before planishing.


Insde view of the joined panels fitted on the wireform which is upside down.




The joined panels after planishing. Far from perfect even after some hours. The metalfinishing takes forever.


To be continued.

[Steve Murphy]

Looks good Dave, you’re getting there.
cheers
steve
PS forgot to mention Evan Wilcox over on Instagram posts a lot of instructional alloy tank making stuff too.

[OldnEK]

Looking Good Dave, I will be interested in how your knee locks turn out as Im thinking of doing something similar to My Guzzi.