Monday 27 August 2012

Tank fun

So I've spent most of this weekend working on the tank for the XS. After TC got me to chop the original tunnel out of it, it was time to start putting a new one together. First thing was to bend up some 1mm sheet steel. I do this in a very precise and accurate way using laser measurements and jigs etc.


With that bent up I slapped the tank on it and went round cleaning up and evening out where I had cut the original tunnel out. Running through this tank are some support beams that originally went straight through the tank from front to back and also formed the mounting lugs (but I cut those off!!). So to make this new tunnel fit, it needed a kink in it to form around these beams. Hopefully that makes sense and you can see what I mean from the pic below.

  

I'm skipping ahead a bit but I forgot my camera!! I went round to the Tinslecats house, where I could continue my work under his helpful (mis)guidance. After putting the necessary bends into the tunnel, we cut it down and TC tacked it in place for me.

  

Then I could weld the rest of it up myself.


I left the beams in originally, to help maintain the shape of the tank, but now the tunnel was welded in I cut them out!!


Unfortunately though, this left big holes in the front and back so I made some little pieces to fill the gaps and welded them in (badly).






And that is how it stands for now. As you can see I cleaned up the welds which has revealed various little holes and imperfections that need sorting out, but for now I'm happy as it. It looks great on the bike, but like a dork I forgot to take a picture!!!