Make your own tank pad ?

[HOS]

Was faffing about last week making my own tank pad for the Zeph11.
The vast majority of "off the shelf" tank pads are for sports bikes.
ie: wide at the top and narrow at the bottom.
Totally unsuitable for anything other than that shape of tank.

Carbon fibre sticky sheet has been around a decade or so now and Motrax UK are one of the biggest suppliers. I use carbon sheet and not carpon effect sticker sheets. The Motrax stuff is carbon as you will see in a bit. It comes in A4 size sheets or some stockits have A3 sized. The sheet is quite flexible and is adhesive faced one side with the usual peel off paper covering.

The great thing is you can make your own "one off" design. The size of design is irrelevant as you can fit more than one sheet together.
The sky is the limit for what you can cut into this sheet.

I`m sure you appreciate it need not be just a tank pad, you can make a design in carbon sheet for anywhere on your bike.

[HOS]

I needed to work out a design and an overall shape on the pad.
The design was the hardest part for me, the overall size and shape was dictated to a fair degree by the shape of the tank above the seat. ;)

I looked at tribal designs and Celtic stuff but could`nt find anything that would leave enough meat in the carbon sheet.
So although its not an original idea, I chose a tyre tread pattern.
After scouring the interweb I found a Pirelli tread I like:

http://www.asfphotos.com/upload/1289085976.jpg


With the basic size and shape allready established from measuring the area of tank it was then a question of drawing the design accurately on the Big Etchasketch or as its more commonly known AutoCAD.

Heres the design:
http://www.asfphotos.com/upload/1289093669.jpg

[HOS]

Might be useful to have the parts and tools list:

1. A4 sheet of sticky backed carbon.
2. Good set of ultra sharp craft knives. (Stanley knives arent good enough for this job)
3. Cutting board.
4. Sticking tape for use while cutting.
5. Duct tape for locating on the tank.
6. Heat gun or the Mrs hairdryer.
7. Some clean rag.
8. Kitchen roll.

I havent listed AutoCAd or a PC/printer as any design can be hand drawn onto paper.;)

[HOS]

On with the job.

Craft knife set:
http://www.asfphotos.com/upload/1289153822.jpg


After printing the CAD design (template) out on plain paper at 1:1 on a normal PC printer. Tape the carbon sheet onto the cutting board and then tape the paper design ontop of the carbon sheet.

From there using the sharp blades and the template, cut right through all three layers.
http://www.asfphotos.com/upload/1289111364.jpg


Once its all been cut out, remove the template and take time to clean it up and remove the loose carbon fibres at the edges !
This is why you need sharp blades, because the carbon will splinter like hell if you do`nt !

http://www.asfphotos.com/upload/1289064839.jpg

[HOS]

Notice I`ve left a couple of tags holding both sides together ;)

From this point we go to the garage and "offer it up", not sticking it down yet.
http://www.asfphotos.com/upload/1289161484.jpg


Now to accurately locate the tank pad ready for fitting. Nothing more naff looking than tank pads fitted out of line !
I`m using weak duct tape that I know is safe on paint. So be extremely careful with what you use or you can damage your paintwork !
Once the tank pad is positioned spot on, I then put duct tape around it to locate it when fitting.
http://www.asfphotos.com/upload/1289103348.jpg


Now take the loose fitted tank pad away because I have more work to do inside.

http://www.asfphotos.com/upload/1289114835.jpg

[HOS]

Final stages are to put some more duct tape across the whole tank pad ready for fitting.

Two reasons:
1. To hold both sides together while I cut out the two seperating tags.
2. To use to hold the tank pad and place it on the tank, thereby not touching the adhesive on the pad itself.

We have all wrecked stickers by having greasy or dirty fingers ?


http://www.asfphotos.com/upload/1289085159.jpg


http://www.asfphotos.com/upload/1289153211.jpg

[HOS]

Back to the garage to prepare the tank.

I used a heat gun on its lowest setting and with caution !
Your Mrs hairdryer might be more suitable if you`re unsure.
Be extremely careful or you will blister your paint !!!
This is to dry out the tank surface and the heat will enable the glue to stick better and the carbon sheet to flex better over the curves in the tank.

http://www.asfphotos.com/upload/1289109701.jpg


Any design will have to consider the curvature of what you are applying to. If you have solid sheet with too few cut outs, it will not curve very well and will end up crinkled on the tank. So you have to build in that flexibility to your design.

Now I wipe down the tank using clean and dry kitchen roll to remove any grease. It always works for me and avoids degreasing solvents on the paint. Nice paint, do`nt want to spoilt it :)

http://www.asfphotos.com/upload/1289102656.jpg

[HOS]

By using the setting out duct tape you did the dry run with, you can now remove the paper face to the adhseive side and lay the carbon tank pad down while holding the white duct tape "straps".

It is now accurately in position.

http://www.asfphotos.com/upload/1289156346.jpg


All that is left is to very carefully remove the tape and polish the tank to ensure any tape residue is gone.

http://www.asfphotos.com/upload/1289150263.jpg


http://www.asfphotos.com/upload/1289090441.jpg



You might think thats a bit OTT ?

But if its worth doing ?..... ;)



A word of caution:
Beware the duct tape on your paintwork ! If in doubt do`nt use duct tape ! It can wreck your paintwork !
I just happen to know this stuff I used is OK.

[Gitzy]

As much as I admire your handywork Hos, I think one of these would have looked heaps better on the Zeph tank.. Good work anyway..

http://www.asfphotos.com/upload/1289081801.jpg


http://www.asfphotos.com/upload/1289147399.jpg

[HOS]

quote:Originally posted by Gitzy

As much as I admire your handywork Hos, I think one of these would have looked heaps better on the Zeph tank.. Good work anyway..

http://www.asfphotos.com/upload/1289081801.jpg


http://www.asfphotos.com/upload/1289147399.jpg




Thanks mate.

Yeah I saw a few good tank pads for Kwaks much like those, but they are too narrow for the Zeph tank shape. Those type are great for sports bikes where the tank is comparatively narrow by your plums. ;)