gas tank ideas

[gwcrim]

So, things are moving along, parts are ordered and arriving.  The one big hurdle left is a fuel tank.  What options are there other than smooshing in the bottom of a stock tank?  I'm thinking about using a plastic welder and sectioning a Clarke oversized tank. 

[Suva]

Check last two pages of k5 rebirth.  Yeoman gave me a few words of wisdom on that

[Brute]

Not sure what was said there but I would not trust a plastic welded tank without perfecting the process first. Having said that I have done a fair amount on various items and would not do it on a gas tank unless it was just for show.
Just read the K5 rebirth and the "new' part" could be why I have had trouble and would not trust a welded tank. A future experiment!

[gwcrim]

OK, lots of advise on what NOT to do.  We ride woods and having an oversize tank is pretty much mandatory.  Ideas?

[Brute]

What I got from K5 rebirth thread is a new plastic tank CAN be successfully cut and plastic welded. One other option (difficult and expensive) would be to weld up an aluminum one.
Fiberglass used to be an option but the ethanol in fuel has screwed that up. If anyone wants to read a boating study about ethanol ruining fiberglass tanks here is a link.
https://www.boatus.com/seaworthy/fueltest.asp

[yeomans]

 When I originally had the tank welded I was told the tank had to be new , the left over oil residue in a used tank from pre mix will mess up the plastic welding process.
I was worried about welding at first as well. The guy that did the work has owned his own plastics company for over 25 years.
 He had done 2 other tanks for a guy in town before mine. Both of these tanks have ran the past two seasons with no issues, and both bikes are being raced. Both are two stroke CRs
 The tank was also tested with pre-mix before it left his shop for leaks and held for two weeks, but still has not run next to my hot cylinder head yet.
I've also thought about running one of those pro circuit heat shields like the four strokes use, to help to cut down on additional heat and help to hide the welds.

[gwcrim]

 I did find a company around here that fabricates polypro but of course, they won't touch a fuel tank.  I think I read somewhere that kayak shops can do this stuff so maybe I can go that route.  If nothing else, I'll just do it myself.  Ya, that's it.  Waste $300 and ruin a new tank.

[zz3gmc]

What year chassis are you guys using?

[yeomans]

What year chassis are you guys using?

I'm using the 99-02 kx 250 frame.

And yeah, the idea of ruining the tank scared me at first too.
I know the standard tanks for the 250's weren't an option for me, they don't hold enough fuel.
Even on my 250 in the woods with friends I'm always the first guy to turn around for fuel reasons, the four strokes they are all on sip gas compared to me

[gwcrim]

02 chassis her too.  I have an 02 250 with an over sized tank on it.  Need a new one though, right?

[Brute]

Geez. Bad enough cutting up an old one. I would cringe on that first cut on the new one! Probably cry just a little too. And drink. Drink a lot. That would help. Hot loose women would help get over it too. Wait. What were we talking about???

[yeomans]

02 chassis her too.  I have an 02 250 with an over sized tank on it.  Need a new one though, right?

Thats what my plastics guy told me anyways. I trusted his judgement, but I couldn't say for sure.
He told me it the Clarke ones were made from low density poly.

[yeomans]

Geez. Bad enough cutting up an old one. I would cringe on that first cut on the new one! Probably cry just a little too. And drink. Drink a lot. That would help. Hot loose women would help get over it too. Wait. What were we talking about???

Lol, Hot loose women and booze help every time

[gwcrim]

Yeomans, would your guy be willing to do a tank for me?  Can you put me in touch?

[yeomans]

I'm not sure if he would, but I can defiantly put you in contact with him.
I have his card around here somewheres, I'll take a look for his contact info today and post it for you.
Not sure if you know we are in Canada though.