XT225 Custom Tank Build

Discussion in 'Thumpers' started by underkill, Nov 20, 2008.

  1. plugeye

    plugeye MC rescue

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    commendable job. these ideas often turn into time-suckers, i've been down similar roads many times, not always liking the results, but the learning experience is worthwhile. i hope it works out for you & thanks for bringing us along for the journey. i love it myself.
    #61
  2. underkill

    underkill Horsepower Junkie

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    Well I'm pleased with the Ospho so far. Their website and directions suck, but I figured after dinner sometime it should be all dry and I can start the tank liner. I've been keeping the tank warm with a heat gun so that should help a little bit. Anyway, it started dissolving rust almost immediatly and the inside of the tank now looks like this:

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    as much as you can see anyway... Either way, there used to be big spots of rust down there and now its more silver implying way less rust.. its more impressive in person.. :D

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    Theres the Kreem tank liner... Hopefully i'll be able to tell y'all about how freaking badass it is tomorrow... :rofl

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    There she is with another coat of primer and a better picture... not looking too shabby really! i'm pleased!

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    The inside of the side scoops isn't very pretty at all... but will rarely, if ever, be seen... I have plans for it all... you'll see!

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    Also changed the oil on the 640 today and had the front off... looks rather snazzy doesnt it? hmmmmmmmmmm! :evil
    #62
    henrrytuan likes this.
  3. LukasM

    LukasM Long timer

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    Starting to look very nice for sure!

    I'd be interested in how much the thing weighs when it's all done with paint, bondo etc.
    #63
  4. underkill

    underkill Horsepower Junkie

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    Well it'll be a heavy one that's for sure... Figure the stock tank was metal, we added some metal, left some stock metal for inner baffles, added metal during brazing, added lead during soldering, and then add bondo and paint..
    :rofl..........:cry
    ohwell though, for just a "road trip" tank i'm not too concerned about it.. I still have the little stocker for offroad duty...

    The bike has no balls anyway, adding 50#s of tank and fuel won't really make that big of a difference, it'll still be slow.. :D
    #64
  5. Blinkerfluid

    Blinkerfluid Long timer

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    It weighed right around 10 lbs before we started the brazing/finishing work.. Shouldn't weigh more than 11 lbs when its all done.. so not too bad.. not sure how much the stock tank weighs, so no comparisson there.
    #65
  6. Reposado1800

    Reposado1800 Juicy J fan!

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    Very nice.
    #66
  7. LukasM

    LukasM Long timer

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    That's not bad at all. As a comparison, the stock metal tank on the DR650 weighs about 9 lbs and only holds 3.2 gallons.

    I'd still use the new tank to pull a mold and lay one up in CF/Kevlar though, probably 1/3 of the weight :D
    #67
  8. DaFoole

    DaFoole Well Marbled... Supporter

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    Nice Work!!!:clap :clap Can't wait to see the finished product! I wish I could do stuff like that....:cry Too lazy/busy/stoopid......:lol3
    #68
  9. underkill

    underkill Horsepower Junkie

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    The actual making of the tank was pretty easy.. its the getting it to not leak part that was the hardest! I had considered making a 'glass one before we did the metal one, but jason wanted to play with metal so we went that route... not to say i wont try one again with glass.. i'm better at that than I am with metal anyway... Maybe i'll try a rally fairing... :evil

    Anyway, got the Kreem liner in last night. Im sure it works better on tanks without 'baffles' .. its very thick and hard to get everythign coated because you can't see down into the hole... I hope I got it all.. and it smells gnarly... :huh
    #69
  10. RimBenty

    RimBenty Greg - Bender of Rims

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    MAN! How big did you make that tank? It looks huge compared to that laundry basket in the back ground! :huh :rofl :lol3

    #70
  11. underkill

    underkill Horsepower Junkie

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    HAHA nice.... yeah its a 42 gallon... should get me around the world a couple times... don't like stopping for gas... EVER! :rofl
    #71
  12. velosprocket

    velosprocket Been here awhile

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    Cool thread, thanks for sharing!
    #72
  13. underkill

    underkill Horsepower Junkie

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    aaaaaand UPDATE!!!

    The tank fits and doesnt leak!!!!! :eek1:clap:freaky

    Here's some pics:
    (side panels aren't on and halfway through the windshield install, dont mind the mess!)

    [​IMG]

    [​IMG]

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    So whatcha think? Still have to finish the silver base coat and decide what else I want to paint on it.. but.. I LIKE IT!!!!! YAY!!!!!!
    #73
  14. johnnyandjebus

    johnnyandjebus Been here awhile

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    underkill


    but.. I LIKE IT!!!!! YAY!!!!!!

    What you said!! Great job:clap:clap
    #74
  15. mouthfulloflake

    mouthfulloflake Not afraid

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    carry a bar of soap with you the first couple of test rides.

    it should plug a gas leak long enough to get you home, assuming its not dripping onto to the exhaust header or sparkplug, or anything like that.

    looks really good though!
    :freaky
    #75
  16. Reposado1800

    Reposado1800 Juicy J fan!

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    If you do find a wet spot I would sand around it down to bare metal and patch with fiberglass resin. Bondo is porous and won't stop a leak.
    #76
  17. MasterChief

    MasterChief Adventurer

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    You guys are doing a great job and have given me an idea. just happen to have a spare tank laying around:rofl
    #77
  18. GsVs

    GsVs Goin' Somewhere

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    :clap Looks like your XT225 has turned into an Adventure Touring XT ! :clap
    #78
  19. chronos

    chronos Been here awhile

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    Much respect for tackling without the experience that would come in useful. I cut my teeth doing bumper repair and paint. What you've got there is some serious complexity! Like it's been said, use the resin and float a lot of bondo then sand, sand, sand. From the pics, I think you're a few steps away from being able to use the primer. You can also spray primer in many coats building a thick layer, then sand, then more primer, then hand sand eventually. Then spray the color on lightly, see where you need more primer, filler, and you'll be glad you did after spending so much time on fabrication..

    Outstanding job and the tank is looking like it should have been on there stock! :clap
    #79
  20. Sam Simons

    Sam Simons Been here awhile

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    Well Done,underkill!! You chose a very challenging 1st project and persevered to a successful completion....Great!

    Sam in Indiana
    #80