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

Video Walk Around of Tank

Step 1: Materials 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.

  • 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

  • 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

Another thing that is highly recommended is to use a product from POR-15 called US standard tank sealer because the ethanol in gas can eat the epoxy and fiberglass. I only found out today and placed an order for this product.
Check out these custom motorized bicycle gas tanks - https://www.indiegogo.com/projects/imperial-cycles-motorized-bicycle-custom-gas-tank/x/11744031#/
That is sick!! I have the same rear rack too lol.
Nice. I will be doing the same for my motored bike
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Cool. You do great work. I'm looking at building one of these for my son's, where did you come up with the motor set up?
- got my motor kit from rawmotorsusa.com before they raised the price. It was $180 shipped and now they sell them for $230 +shipping. You can probably find them cheaper on ebay or from another supplier.
Great 'ible'. I have one of these motor kits and the gas tank rusted in just a year. So I will use your creation to make a contoured one for my bike. I was thinking about somehow using pvc pipe painted to the same color of my frame and making it look like it was part of the frame as a fuel tank. <br><br>If I can use a large enough diameter it would hold more than a gallon. So out to the shop I go.
Sounds good. Need to seal the tank. I made the mistake of not venting the gas cap and the side of the tank collapsed.
Great instructable!<br><br>I might make a tank using this technique.<br><br>Too bad i wasn't able to join the contest, i'm making a custom chopper motorbicycle but can't enter now =(
Thanks. Glad you like it. <br><br>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. <br><br>I hope to see the chopper when your finished.
very nicely done, I was going to mention that gasoline has bad effects on fiberglass but you covered that in your comment, you may want to add it as a step to your ible though
I used a &quot;fuel safe&quot; epoxy resin called Z-POXY Finishing Resin. I have used POR-15 products on a car restoration and loved it. I figure its better to be safe than sorry to seal the tank because I don't want two weeks of work to go down the drain.
Cool, about a week ago, I bought an engine for my bike that looks just like that one, Great Job.
EXCELLENT!<br><br>Thanks for sharing this instructable.
Thank you. Glad you like it.

About This Instructable


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Bio: Full time College student (Computer Science and Engineering Major) with a passion for building stuff with whatever is on hand at the time. Been tearing ... More »
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