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Seeing that Instructables had a bicycle contest, I knew I had to enter the contest with this project. It took two weeks to get the materials and put it together. So here is the results.
I bought a motorized bicycle kit about a month ago and I did not like the look of the cheaply made tank that comes with all the motorized bicycle kits. They use cheap metal and when I received the kit, the gas tank had a little bit of rust inside and had a dent on the side of it. The petcock that comes with it also leaks and the inline fuel filter sucks.
So I decided to make my own tank using fiberglass, styro-foam, epoxy resin, and wooden dowels. It is simple, but time consuming to make a custom made tank as shown in the following steps. I tried to use wire mesh as a base for the tank, but the shape I made had too many curves for it to form.
Do Not use the green styrofoam that I show in the pictures because that foam does not dissolve with any solvents.I planned to use Acetone to melt the foam after the fiberglass was laid, but ended up cutting a hole in the fiberglass and removed the foam with a dremel and then patched it.
This instructable involves using dangerous tools and chemicals. Safety should be your number one priority
I bought a motorized bicycle kit about a month ago and I did not like the look of the cheaply made tank that comes with all the motorized bicycle kits. They use cheap metal and when I received the kit, the gas tank had a little bit of rust inside and had a dent on the side of it. The petcock that comes with it also leaks and the inline fuel filter sucks.
So I decided to make my own tank using fiberglass, styro-foam, epoxy resin, and wooden dowels. It is simple, but time consuming to make a custom made tank as shown in the following steps. I tried to use wire mesh as a base for the tank, but the shape I made had too many curves for it to form.
Do Not use the green styrofoam that I show in the pictures because that foam does not dissolve with any solvents.I planned to use Acetone to melt the foam after the fiberglass was laid, but ended up cutting a hole in the fiberglass and removed the foam with a dremel and then patched it.
This instructable involves using dangerous tools and chemicals. Safety should be your number one priority
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Signing UpStep 1Materials and Tools
There are many materials and tools used in this project. It can be very expensive to build your own tank, but it is worth it in the end because no other motorized bicycle will have the same tank.
Materials-
Tools-
Materials-
- Styro-foam
- Small Wooden Dowels
- Styro-foam Safe Glue
- Fuel Safe Epoxy Resin
- Fiberglass Cloth (2-5oz)
- Fuel Spigot
- Inline Fuel Filter
- Cardboard
- Masking Tape
- Marker
- Spray Paint for Finish
- Clear Coat
- Primer
- Copper Sheet
- Copper Coupler
- Removable Plug for Coupler
- Flux and Solder for Copper
- Thread Lock (Optional)
- Scrap Piece of 1/8th inch plywood
- Body Filler (Bondo)
- Dust Mask (highly recommended)
- Gloves
- Measuring Cups
- Four nuts and 2 threaded rods.
- Acetone
Tools-
- Bandsaw
- Rasp
- 320 Sandpaper
- Socket Set
- Gloves
- Spreader
- Propane Torch
- Razor Knife or Sharp Scissors
- Tin Snips
- Drill with Drill Bits
- Scroll Saw (Optional)
- Scotch-Brite Pad
- Sanding Disks
- Dremel with Sanding, Wand Attachment, Brass Brush, and Cut off Wheel
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If I can use a large enough diameter it would hold more than a gallon. So out to the shop I go.
I might make a tank using this technique.
Too bad i wasn't able to join the contest, i'm making a custom chopper motorbicycle but can't enter now =(
You can always work on the instructable for your chopper motorbicycle and then decide if you want to publish it if you see a contest prize you want and have a chance at getting.
I hope to see the chopper when your finished.
Thanks for sharing this instructable.