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Old 01-19-2012, 08:11 AM   #391
johnwesley
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sounds good, they probably have the molds laying around.
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Old 01-19-2012, 07:24 PM   #392
JimmyTheHog OP
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xrscooterman - Thanks for the tip on the plasitc tank. I'll check it out. I wonder if its the same tank as someone posted a few pages back that shows the tank on a sportster. 4.2 gal is better than 2.75, but still not as much as id like though.

When I talked to IMS, they also mentioned that their tanks were not street legal (non-dot?). I know that lots of us buy them anyway and use them on the street for dual-sporting though. Not a problem.

I have been busy looking for an alternative solution though and found "Evan Wilcox Hand Formed Metal" - He has agreed to make me an aluminum hand formed tank ~5.5 gal. I mailed my check a few days ago to get on his calendar which is 6-8 months out. If you havent seen his work, check it out - Incredible ! Here is a Buell tank he did - picture from his web site. He may be able to also do a "limited" production of mine when done. I'll add details as I get them, but this will be a long term project.

http://www.wilcoxmetal.com/index.htm

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Old 01-20-2012, 06:32 AM   #393
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Quote:
Originally Posted by johnwesley View Post
sounds good, they probably have the molds laying around.
Just checked with Acerbis - Brian F replied that these are no longer available (N/A).
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Old 01-20-2012, 07:41 AM   #394
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Quote:
Originally Posted by JimmyTheHog View Post
xrscooterman - Thanks for the tip on the plasitc tank. I'll check it out. I wonder if its the same tank as someone posted a few pages back that shows the tank on a sportster. 4.2 gal is better than 2.75, but still not as much as id like though.

When I talked to IMS, they also mentioned that their tanks were not street legal (non-dot?). I know that lots of us buy them anyway and use them on the street for dual-sporting though. Not a problem.

I have been busy looking for an alternative solution though and found "Evan Wilcox Hand Formed Metal" - He has agreed to make me an aluminum hand formed tank ~5.5 gal. I mailed my check a few days ago to get on his calendar which is 6-8 months out. If you havent seen his work, check it out - Incredible ! Here is a Buell tank he did - picture from his web site. He may be able to also do a "limited" production of mine when done. I'll add details as I get them, but this will be a long term project.

http://www.wilcoxmetal.com/index.htm

..

he does awesome work and it will look good on the bike when he is done. I know his work does not come cheap any idea on price from a production standpoint?
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Old 01-20-2012, 01:16 PM   #395
SimpleSimon
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Makes you wish one could form some dies and press a few of those tanks out.
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Old 01-20-2012, 07:24 PM   #396
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Quote:
Originally Posted by johnwesley View Post
... any idea on price from a production standpoint?
No, not yet, but Im waiting for a reply. Im curious too.
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Old 01-27-2012, 04:54 PM   #397
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Should be a fun ride.
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Old 01-27-2012, 09:57 PM   #398
woodnbow
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Jimmy, is the front end from your 03 525 KTM? Sharp looking bike, very nicely done!
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Old 01-28-2012, 07:29 AM   #399
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KTM Front End

Yes - 2003 KTM 525 EXC, but I replaced the springs with MX Tech 0.6kg/mm springs and had Hlebo do the revalving. I started with 0.7's, but they were too stiff for me at ~200lbs. Now, feels right and very plush.

The triple clamps and stem are from Applied Racing - for an 03 KTM 525 model. Stock KTM head bearings or aftermarket work (I used Moose Racing p/n 0410-0034). Just remove the HD bearing races and tap in the KTM races, and bolt it together.

You will need to modify the top dust seal though. Either use the stock HD dust seal and make the hole bigger to fit over the larger dia KTM stem, or use the KTM dust seal and trim the height so it dosnt hit the top tube.

Pretty straight forward install Here is a page from my build notes on it...

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Old 01-28-2012, 07:37 AM   #400
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Sterring Stop

.... I should add that I also made a steering stop adapter bracket to prevent the fork tubes or triple clamps from hitting the Storz gas tank. It still has nearly the full lock-to-lock turning, but wont hit the tank.

Here are the notes on that. The bracket bolts to the Applied Racing triple clamp bottom and stops at the stock HD block on the stock frame.

...
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Old 01-28-2012, 07:56 AM   #401
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Quote:
Originally Posted by woodnbow View Post
Jimmy, is the front end from your 03 525 KTM? Sharp looking bike, very nicely done!
Thanks! Here is another page from my notes. Note that when you put the stiffer spings into the KTM forks, you may need to turn down the plastic spring guide to make them fit. I did for the 0.7 spings. The 0.6's might be ok - not sure since I didnt start with them. 0.6's have smaller diameter spring wire.

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Old 01-28-2012, 12:17 PM   #402
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Quote:
Originally Posted by JimmyTheHog View Post
Thanks! Here is another page from my notes. Note that when you put the stiffer spings into the KTM forks, you may need to turn down the plastic spring guide to make them fit. I did for the 0.7 spings. The 0.6's might be ok - not sure since I didnt start with them. 0.6's have smaller diameter spring wire.

..
Wow! thanks Jimmy, that's more than I was looking for but exactly what I need! I'm not cleared for actual physical work yet but at least I can start gathering parts, we've still got at least 8 weeks of winter left here, Hope to have my Sport on the road and off for the spring thaw!
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Old 02-01-2012, 07:32 AM   #403
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Quote:
Originally Posted by johnwesley View Post
..... I know his work does not come cheap any idea on price from a production standpoint?
Just got the message from Evan on the tank - he wont know the cost of a production run version until he makes the first one. So, we'll have to wait and see.
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Old 02-01-2012, 05:30 PM   #404
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Thumbs Up

I am fairly new to this group even though I have been in the business for some time and you probably heard it all before, but I must say, that your build is the most inspiring task I have seen in a very long time. Well thought through and well executed. A prime example on how it should be done.

I know Willy G wouldn't agree, but the hell with him.
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Old 02-11-2012, 06:01 PM   #405
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Got my bike back last night with the new 1250cc kit, cams, carb rejet - I was having serious withdrawls. Took it out for a short ride - extra power feels great, but still breaking it in, so not reving it too high yet. The real fun will begin after 150mile break in.

I went with black cylinders - thought it went well with the color scheme of the bike. Here are a few pics..



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