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After stirring the solution, you will pour it directly onto the form.
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I mixed the epoxy 30cc's (about two tablespoons) at a time. Then you need to put on some gloves and put the foam form onto the sheets of newspaper. Next thing you need to do is get your measuring cups (I took some medicine cups from work so the epoxy measurement is accurate) and you need some stir sticks. First thing you do is lay many sheets of newspaper down on your work surface. You will have to sand the fiberglass and epoxy down so having the strips overlap is not a problem. The best method is to use strips of fiberglass cloth and lay them side by side. Using a sheet for an area is not a good idea as it will cause air bubbles in the fiberglass.
#CUSTOM POSTIE MOTORBIKES HOW TO#
All I can tell you is the best method for applying the fiberglass and some tips on how to apply it. I can not tell you step by step on how to do this part exactly because everyone will have a different shape. I put 5 oz cloth as a base on the top and bottom of the tank and found it too hard to mold to this shape. It took me 3-4 days to fiberglass the whole tank with two layers of 2 oz cloth and 6 hour cure time epoxy. This is the main part of this instructable. Remove the wooden dowels from the form after the foam has been glued securely Since my tank is inside a void in the frame, I had to make sure it was small enough to fit after the tank is created. You will need to make the foam a little smaller than the final tank due to the fiberglass cloth and epoxy resin. After the basic shape was cut out, I used a sanding block with 320 grit and a rasp to shape the tank as I pleased. Your design for the tank as viewed from the top will be different then mine depending on the style that you want to achieve. Before sanding, it looks like a coffin as viewed from the top. I then used a bandsaw to cut these two lines to create the teardrop shape. I wanted to make a tear drop style tank so after measuring 1 and 1/2 inches on each side of the center line at the rear of the tank, I used a straight piece of cardboard and created a teardrop shape starting about 4 inches from the front of the tank to the two marks on the back of the tank. I then found the center line of the tank on the part that will be the top. The dowels in the foam will cause a little resistance when you reach them while cutting. Cut just outside the line you made so that you can use the rasp or 320 sandpaper to hone the material down to the shape you want. Make sure your table is level on the bandsaw or else you will end up with one side of your tank being a little larger than the other. Use a bandsaw in order to cut out the basic shape. After the glue has dried, remove the masking tape and then take the cardboard template you made in the step before and draw the pattern onto the foam using a sharpie. You then stick some dowels into the form to further strengthen the foam. You need to glue these foam blocks together and use masking tape in order to put pressure on the pieces being glued together. Styrofoam is the only foam I know of that dissolves with any solvent.
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I don't recommend using it if you don't want to cut a hole to remove the foam. The foam is the type that you stick artificial flowers into as a base. The form for the gas tank is made of the green foam that you can pick up at arts and craft stores.
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Safety should be your number one priority Video Walk Around of Tank This instructable involves using dangerous tools and chemicals. I tried to use wire mesh as a base for the tank, but the shape I made had too many curves for it to form.ĭo Not use the green styrofoam that I show in the pictures because that foam does not dissolve with any solvents.I planned to use Acetone to melt the foam after the fiberglass was laid, but ended up cutting a hole in the fiberglass and removed the foam with a dremel and then patched it. It is simple, but time consuming to make a custom made tank as shown in the following steps. So I decided to make my own tank using fiberglass, styro-foam, epoxy resin, and wooden dowels. The petcock that comes with it also leaks and the inline fuel filter sucks. They use cheap metal and when I received the kit, the gas tank had a little bit of rust inside and had a dent on the side of it. I bought a motorized bicycle kit about a month ago and I did not like the look of the cheaply made tank that comes with all the motorized bicycle kits. It took two weeks to get the materials and put it together. Seeing that Instructables had a bicycle contest, I knew I had to enter the contest with this project.