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Plastic fuel tank mod for earlier gen monsters

Started by FATTIRE, February 23, 2015, 04:40:47 PM

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FATTIRE

Let me start this off by saying there is a pro and con to everything. The pros to this is you don't really have to ever worry about your tank getting dented again. Also your bike is a few pounds lighter. The cons is if you use gasoline with ethanol, your tank will likely swell due to the nylon absorbing the ethanol.  Also to keep your tank from swelling, you will need to use gas with out ethanol. Having said that, you will have to remove the ethanol yourself by adding water to your fuel, shaking the can, waiting for the water/ethanol to settle at the bottom. Then remove the water/ethanol mixture as they bind together. All that is left is pure fuel. If you can deal with that, you can deal with the tank mod. So here is how I did it.

I have a 1999 M750. I bought a 2007 Monster S2R plastic fuel tank in pretty god condition.
Next I bought a 1/8" 5.5in mild steel disk. I then took masking tape placing it all around the fuel pump flange inlet.
Next I then cut a perfect circle around the entire flange area.  Once complete with that I used a pencil to shade over the screw holes to let me know exactly where to drill the holes in the steel disk.
Next I took the masking tape off the tank placing it perfectly on the steel disk.
Next I took a steel punch marking the center of all those holes.
Next I removed the masking tape and drilled out the holes.
Next I went to Home Depot and bought a brass 3/4 inch Union fitting which had all the parts I needed to complete the fuel sensor portion.
Next I took a hole saw and boared out part of the Union fitting. The rounded part you can throw away. Keep the nut as it is exactly as what you have on your metal tank. Just brass.
Next I marked a spot on the steel disk a made a small with a punch.
Next use a 1" hole saw to make a perfect circle.
Next I went to auto zone and bought a 5/16 fuel fitting.
Next I again made a mark on the steel disk with a punch.
Next I then drilled out a hole to the exact size of the fuel fitting.
Next I then took the pieces fit them together and tig welded them onto the steel disk.
Next I cut of the inside tank portion of the disk making it flat.
Next step is to powder coat the part for optimal protection. 
That's it.

You will then have three hoses that connect to your new plastic tank just as you did your steel tank. You will have a bleed line, a drain line, and a fuel delivery line. Connect them all and you are all set.

I would have posted pics but this does not show an option. I will put them up if someone can assist.  Thanks and enjoy the mod.
99' M750 (Current), 02' RC51 (Sold), 99' 996 (Stolen), 05' r1(Stolen), 02' ZX6R (Sold),
Best Motorcycle Insurance is a Rottweiler.  You will still have your bike and perhaps gained an arm or leg.....

FATTIRE

Refer to www.ducatimonster.org for pics.  Look for the thread in the mods section.  Thanks.
99' M750 (Current), 02' RC51 (Sold), 99' 996 (Stolen), 05' r1(Stolen), 02' ZX6R (Sold),
Best Motorcycle Insurance is a Rottweiler.  You will still have your bike and perhaps gained an arm or leg.....

ducpainter

"Once you accept that a child on the autistic spectrum experiences the world in
a completely different way than you, you will be open to understand how that
 perspective
    is even more amazing than yours."
    To realize the value of nine  months:
    Ask a mother who gave birth to a stillborn.
"Don't piss off old people The older we get, the less 'Life in Prison' is a deterrent.”



FATTIRE

Thanks for the help with the pics.  Ill get on it and put a URL.  I would go on the other site if I was paid LOL. 
99' M750 (Current), 02' RC51 (Sold), 99' 996 (Stolen), 05' r1(Stolen), 02' ZX6R (Sold),
Best Motorcycle Insurance is a Rottweiler.  You will still have your bike and perhaps gained an arm or leg.....

ducpainter

Quote from: FATTIRE on February 23, 2015, 05:18:58 PM
Thanks for the help with the pics.  Ill get on it and put a URL.  I would go on the other site if I was paid LOL. 
You can't pay me enough for the visual assault...the intellitext...and the lack of community...but that's just me.

BTW...I've shipped a lot of tanks and the plastic tanks are no lighter in my experience.
"Once you accept that a child on the autistic spectrum experiences the world in
a completely different way than you, you will be open to understand how that
 perspective
    is even more amazing than yours."
    To realize the value of nine  months:
    Ask a mother who gave birth to a stillborn.
"Don't piss off old people The older we get, the less 'Life in Prison' is a deterrent.”



stopintime

252,000 km/seventeen years - loving it

Howie

Quote from: ducpainter on February 23, 2015, 05:22:16 PM
You can't pay me enough for the visual assault...the intellitext...and the lack of community...but that's just me.

BTW...I've shipped a lot of tanks and the plastic tanks are no lighter in my experience.

Me too.

There will be a weight reduction due to diminished fuel capacity :P

FATTIRE

Well, i put this on here to help others that wanted to due this mod.  I wanted to do this as it was a custom project.  The only thing that makes this bike a monster still is the title as it has been converted with an MV Agusta tail and exhaust system as well as engine.  Only a monster frame, wheels, and tank.  Pictures were going to be posted but due to my LACK OF COMMUNITY, I dont care to post anymore on this subject.  As I spend 3/4 of every year overseas with the government, I dont have time to play who wants to post the most.  Good luck.  THAT IS ALL 
99' M750 (Current), 02' RC51 (Sold), 99' 996 (Stolen), 05' r1(Stolen), 02' ZX6R (Sold),
Best Motorcycle Insurance is a Rottweiler.  You will still have your bike and perhaps gained an arm or leg.....

SpikeC

Spike Cornelius
  PDX
   2009 M1100S Assorted blingy odds and ends(now gone)
2008 Bimota DB5R  woo-Hoo!
   1965 T100SC

silas

Fattire- he meant the lack of community at the other competing / spin off ?   site you mentioned.

Now I'm here to say we want pics or it didn't happen ! Sounds cool.  We don't go to the other side. 

I use tinypic.com.     Super convenient to use.

Ride fast, ride safe
'98 M900, '92 Yamaha TDM850

ducpainter

Quote from: silas on February 24, 2015, 09:22:32 PM
Fattire- he meant the lack of community at the other competing / spin off ?   site you mentioned.

Now I'm here to say we want pics or it didn't happen ! Sounds cool.  We don't go to the other side. 

I use tinypic.com.     Super convenient to use.


Yeah...he definitely misunderstood. :-\
"Once you accept that a child on the autistic spectrum experiences the world in
a completely different way than you, you will be open to understand how that
 perspective
    is even more amazing than yours."
    To realize the value of nine  months:
    Ask a mother who gave birth to a stillborn.
"Don't piss off old people The older we get, the less 'Life in Prison' is a deterrent.”



brad black

across the various forums i frequent, there seems to be a real rise of hissy fitters these days.
Brad The Bike Boy

http://www.bikeboy.org

kopfjäger

Quote from: brad black on February 25, 2015, 12:42:16 PM
across the various forums i frequent, there seems to be a real rise of hissy fitters these days.

Whole bunch of 'groan' men with skin as thin as onions.  :D
“Woohoohoohoo! Two personal records! For breath holding and number of sharks shot in the frickin\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\

koko64

Trojan horse sent by the other mob, or just a sook? ???
2015 Scrambler 800

Howie