Aluminium fuel tank

May 2015

Viewing posts from May , 2015

Aluminium fuel tank

It’s still not a definite “no” on getting the SV registered in Germany, however with the fibreglass fuel tank it’s incredibly unlikely. So I used my connections from my time out in India to get an aluminium one made up. So, I modified the pattern to be more simple to make in aluminium, and sent it out to India with a friend heading that way

After a few false starts trying to use steel, a hand beaten aluminium tank finally emerged, and was brought back to Germany by one of my other wonderful friends. (Melanie, Juliane and Kunal thank you for being such willing motorcycle parts mules!)

aluminium fuel tank 4

aluminium fuel tank 5

aluminium fuel tank 3

aluminium fuel tank 2

I pressure tested the tank to 1 bar of pressure, so although the surface isn’t 100% perfect, this aluminium fuel tank is well constructed and fuel tight. It should keep the TÜV man happy, should it ever get to that point…

Aluminium fuel tank pressure testing

Aluminium fuel tank pressure testing using a cut up bicycle inner tube at the fuel inlet, just visible on the right.


Full Strip Down before Rebuild

One thing I wanted for sure on the final bike was a black frame, as opposed to the silver one on the development bike. This of course was going to mean a full strip down and rebuild to achieve this. To this end, I bought another low mileage SV650 with a black frame on ebay for a bargain price. The other thing about this new bike is that it’s UK registered – it’s beginning to seem like registering the SV in Germany is going to be an insurmountable hurdle, due to the amount and nature of the modifications. Having the bike registered in the UK is hardly ideal, but it’s the best workaround I can think of for now.


UK SV650 arrives

It’s getting crowded in my small workshop!

SV650 being stripped

Stripping the UK bike down

Having stripped the UK bike down, I decided that I should cut off the left hand lower subframe mounting, as it’s completely redundant in the new design. This of course meant that I would have to completely strip the black finish and re-powder coat it. Not having access to a sandblasting cabinet, it was time to improvise a solution that would allow me to sandblast in the workshop. The great thing about this s that it’s entirely sealed, so it’s really easy to collect the sand and refill the blaster!

Pop up blasting cabinet

A 40 EUR pop-up tent makes an ideal blasting cabinet!

Safety first

Safety first

Sandblasted SV650 frame

Sandblasted SV650 frame.

So with the frame, swingarm and some other parts off to the powder coating shop it’s time to turn my attention to some of the bodywork parts.