New “Tank”

[al_pritchard]

The original “tank” cover has seen better days. Like most of them it’s got cracks running from the threaded inserts back along the upper tank. When I started doing the body work on the tank I started by drilling a hole at then end of the crack to prevent it from growing longer. Then fiberglassed it on the inside. And used a thickened epoxy silica paste on the outside to fill the crack and smooth the repair. It looked perfect, but after a summer of riding the crack re-formed.

So it’s was time to look for a replacement. Recently Gustafson Plastics bought all the molds from Air Tech and started making fiberglass replacement fairings. They rebranded under GP Cycle Works.



It looks like the new tank has a different lip where the hing mounts. At least I think it’s different as I’ve never seen a new original one.


The layup of the new tank is rather thick. So my strategy is to make a simple aluminum bushing and epoxy it into the flange. Then bolt the hinge to the tank. My thinking is the bushing will help minimize any compression stress on the fiberglass. And help male a well aligned hinge.







Also created an aluminum bushing for the hinges.