Alright first a little disclaimer, I am just a dude who has always loved/ ridden bikes, this is the first bike I have built (besides a strip down and tail for my old fzr400)and the second time I have worked with fiberglass so If you have experiance with this stuff you will probobly be appauled by my method of working, but hopefully you can find something usefull.
So here is the back story, this was my best friends fathers bike this the very same bike I learned to ride on when I was 11, in 1996 it ended up on the side of his barn and sat till he gave it to me in november.
Hard parts: 1981 it 175, suzuki gs 250 front end, excell 18x1.85 front and excell 18x2.15 rear, avon 90/90-18 fr and r, vortex clip ons(shimed with aluminum), aluminum pegs, daytona stearing dampener, roaring toyz Hyobusa quick release gas cap(busa caps are one of the simplest and they are 30 mins from my house so I got to look at a few), roaring toyz steel brainded brake line, nissan master cylinder, casewell feul tank epoxy, and pingel fuel valve. I think thats it.
So heres my first mock up for the tank, I wnated the tank to mimick the shape of the expansin chamber.
I used the factory tail light and housing glassed into the new tail, here its all roughed out the tank portion will be come the "fuel cell" here are the first glass sections
originaly i wanted the tank and tail to be one unit that you could prop up like a hood but I scrapped that in the end, here it is as a one piece unit
gas cap recess, I glassed stainless lock nuts into the under side for the cap bolts
the tail, can you tell i am impatient
final shaping, I foamed over the rough "cell" with great stuff and sanded to shap then glassed over
finished tank
Here it is yesterday after my first test ride its a freakin hoot!