budget sv650 cafe racer

gt alex

Been Around the Block
Honda tank cut to match the Suzuki SV frame. Now the decision to remove my functioning tank drain it and cut it in half to mate the Honda tank to the top of my tank. Or make a bottom section from scratch to clear the air filter and fit the fuel gauge and pent cock, sounds easy but I've done tis stuff before and it's not that easy.

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Brodie

Gold Coast, Queensland
DTT SUPPORTER
Video worked that time.
Sounds good.
If I had the choice for the tanks I would go with leaving the stock one alone as a backup and building a custom tank out of the Honda one to fit the new carb and filter neatly underneath.
Been very interesting watching. Keep up the ingenuity.
 

gt alex

Been Around the Block
Video worked that time.
Sounds good.
If I had the choice for the tanks I would go with leaving the stock one alone as a backup and building a custom tank out of the Honda one to fit the new carb and filter neatly underneath.
Been very interesting watching. Keep up the ingenuity.
Exactly what I decided about 2hrs ago
Rough fit for visualisation.
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gt alex

Been Around the Block
Just picked up some 6mm steal rod which I will use to make a skeleton for the base. Thinking of sliding the tank back 40mm if the lines look right and the hinge works, that will make the new design that is much simpler.
If I fit the air cleaner sideways, from the air cleaner forward will be air box and the rear all fuel. Makes for an easer build and probably more fuel capacity.
 

gt alex

Been Around the Block
Last change for others to add input......
I think this will be the final tank position. I need to skirt around the bottom to increase the tank height approx. 2" down to the tank parameter hoop and shape to tank around the seat as a nice custom detail.
I spit the rear to make it a bit wider and the expected skirt height measurements (mm) are written on the take at a few points.
Next is make the base of the tank.

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Brodie

Gold Coast, Queensland
DTT SUPPORTER
Looks good. It appears there will be a bit of an overlap with the current seat though.
What are your plans for that are?
 

gt alex

Been Around the Block
Looks good. It appears there will be a bit of an overlap with the current seat though.
What are your plans for that are?
I am going to shape it around the seat which if I do it right it should look good but also it will let the standard seat hinge position work.
And having the tank that little bit back will give over an extra litre of fuel, and the front part will be all air box.
 

gt alex

Been Around the Block
Looks good. It appears there will be a bit of an overlap with the current seat though.
What are your plans for that are?
Studying the pictures I think it looked better with the top of the tank parallel with the seat what do you think?
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
Comparing the two I think you are right.
If you were to get the top of the tank parallel with the subframe horizontal bars that would be the go in my opinion.
 

pidjones

Over 1,000 Posts
I like the seat/tank angles, but might consider dropping the back of the megaphone a tad to make its angle the same.
 

gt alex

Been Around the Block
I like the seat/tank angles, but might consider dropping the back of the megaphone a tad to make its angle the same.
I am more incline to raise it jus a fraction to match the seat support. If I drop it do match the seat it may impact ground clearance but I will consider it when doing the finishing touches.....Thanks
 

gt alex

Been Around the Block
Getting there I think just 1cm (3/8") more drop over the seat and we are there I think, what do you all think am i missing something? I feels right
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Brodie

Gold Coast, Queensland
DTT SUPPORTER
That looks good to me. Brings a flat look across the top of the bike.
 

gt alex

Been Around the Block
Been making a pattern for the inside shape for the new tank, also pick up some shield gas for the job.

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gt alex

Been Around the Block
Arrived at last a honey come baffle. (like a cat without the catalyst coating)
Since the firs 6" of my megaphone muffler does nothing to quieten the sound level of the bike and I would like to keep the appearance of the old school muffler,
I thought this style of baffle may make use of that part of the muffler without introducing too much back pressure.
I have never used this style before so I will give it a go.
90mm long, flare 51mm, tube od 45mm, id 40mm at the celled section which is 50mm long

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gt alex

Been Around the Block
I was working out fuel capacity for the tank I'm making and a conservative estimate is about 12-13 litres.
I can live with that but I hope it's a bit more when all done.
 

Brodie

Gold Coast, Queensland
DTT SUPPORTER
It's not too bad but more is always nice.
Have you thought about raising the height of the tank?
It looks as if the top of the tank is below the top of the upper fork yoke.
If you were to make them level you may gain another litre or two without affecting the look of the bike too much.
 

gt alex

Been Around the Block
It's not too bad but more is always nice.
Have you thought about raising the height of the tank?
It looks as if the top of the tank is below the top of the upper fork yoke.
If you were to make them level you may gain another litre or two without affecting the look of the bike too much.
I don't really want to raise the tank, if I put fuel volume around the whole tank like the original I can increase volume but that reduces the air box volume. I will look at what I can do. I was taking the easy way out, thanks for pushing me to do better.
 

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