THE SAGA OF THE FIBERGLASS GAS TANK...
Of everything I've built and fabricated on this low rider motorcycle project, the gas tank and the seat are turning out to be the most challenging. I don't have the proper power tools like a shaping hammer that would allow me to make a steel gas tank, which would be my preference. So I am left with only one option... a fiberglass gas tank.
That means sculpting a solid replica of a gas tank using a block of foam. After the replica is hand carved to the approximate dimensions, various fillers are used to do the final shaping. It is a process of applying filler, sanding it smooth, painting the replica with primer... and doing it again, and again, and again, AND AGAIN, AND AGAIN... AD NAUSIUM.
I am getting close to completing the replica, but it has to be perfectly smooth... and I mean "automotive paint" type smooth. If it's not glassy smooth, when the replica is used to make the "female" fiberglass molds, the molds may not easily pop off the replica. Every imperfection is a spot that the molds will want to "stick" to the replica. I've already been informed by several experts that even with a glassy smooth finish on the replica, removing the molds from the original replica will be a major wrestling match. This confirms what I was told by several great guys here, d9canada, pacomotorstuff, doc_rot, Maritime, and jpmobius who kindly and unselfishly took the time to write extensively and in great detail to help me through this process. I could not have made any progress without your advice and I am truly awed and humbled by your generosity. (not to mention the others who offered an encouraging word when I was ready to throw in the towel... I am humbled and grateful for your kind thoughts.... it motivates me to move forward.
I've already had one epic failure on my first attempt to build a fiberglass gas tank, so I am trying my best to do everything perfectly. This is my second attempt... and of the 500 hours of work on this project, roughly 1/3 has been spent on the gas tank. My eyes are starting to glaze over and my head is reeling.... but I don't have a choice. No one builds a tank in the shape I want that will fit snugly to the extreme engine hugging backbone of this frame, which is what allows this bike to have a seat height nearly 14 inches lower than a stock XS 750 se.
I guess I knew it would take time and be a learning experience, but even if I valued my time at minimum wage, the time value of building this tank would easily exceed 1100 dollars. BUT... time I can give and if everything goes well, there will be the satisfaction of knowing that this motorcycle will be unique. (Maybe awful.... but unique) That's what keeps me moving forward. I can't bear the thought of this tank suffering the same fate as the last one...stuck on the tines of a pitchfork like a flaming torch wielded by some crazed posse member looking for a wanton criminal. I mean, burning the last tank attempt was a fun way to blow off a little steam over my first epic tank building failure, but I'm hoping to never have a repeat of that first fiasco. I just want it to be done. I want to ride it. I want to cruise to Sturgis this summer to see and to be inspired by all the cool bikes from the guys that are REALLY great builders.
If, however, by chance, it turns out okay I know I'll feel a certain satisfaction for accomplishing a difficult task that I've never done before.... but I think next time, I crotchet a quilt. LOL! Here's the stages of progress so far.