Fixed the couple of dents in the tank today. Also have a modified tank that will be up for sale. (Has been widened considerably) Don't have a really good picture of it atm but whoever modified it has done an exellent job! Can't even see where it has been cut and welded except if you look inside. Trying out some different ways to make the BMW logo for the side of the tank too.

The fuel pump damper has pretty much melted... does anyone know what I can soak the tank in/ use to break down the sticky rubber stuff in the bottom of the tank?

Thanks, Liam

White vinegar for a week or two and scotch pads.
Regards Martin.

Methylated Spirits aka Metho..at least if it doesn't work some may drink it with boot polish for colouring...dissolves the rubber bits left behind which also get up under the ridge the rubber fits into i used a bent wire coat hanger and small mirror to clean the gunge from under the ridge   ..hate to think what it would do to your gut tho

Finished fixing up and cleaning the tank, got it primed and ready for a little more sanding. My work is getting a 3d scanner this week which I will use to scan the frame, tank etc for a cad model so I can design the seat, fenders, ecu tray and other bits. Should make the job a lot easier. Also thinking about moving the rear shock mount to make the back of the bike flow a bit better. 

Been spending lot's of time working lately but also some CAD in the meantime. Have a seat drawn up as well as the new rear frame. Not sure I'm 100% happy with the seat yet though. Been looking into doing the GSXR fork conversion as well. Also trying to find a rear shock off an R1 (or any 300mm shock) for the new mount. 

Hi Liam,

Looking forward to seeing the new rear end come together as this is something I want to do to my K during our winter here in Michigan. I don't have a CAD scanner so I would love to see more detail from your project as it evolves. 

Cheers
Ken

Got the tank painted and cleared over the weekend as well as picked up a 2010 R1 front end to fit to the bike. Took the good bike to work to scan above the engine so I can draw up the intake bits and pieces to make out of carbon. 

nice job !!

What Charlie says!

Been doing more work on the cad. Scanned above the engine and the throttle body today. Trying to work out where to mount the air flow sensor and new intake (as well as choose filter style) and design the plenum, new trumpets and fuse box to fit in with the new frame. Couple of prototypes being 3d printed helps so much. Printer will be going non stop! Have printed a test for the air flow sensor shroud to test fit which will eventually be carbon and have a carbon lid. Also printed a scale seat, just to look at!

Been working slowly on the air flow sensor and plenum setup as well as drawing up new trumpets. Ended up with a 10L airbox/plenum minus the the air flow sensor approximately 8.5-9L. The system is now a lot less restricted airflow wise. Also worked out and drew up the new rubber boots for sealing/holding the plenum and trumpets to the intake manifold. I need to get a longer throttle cable though... Still need to sort out a filter/intake yet.

cool, be interested to see what you come up with ,,cheers

Woohaa!

I really like the idea of the CAD design and prototyping with 3D printing. This will be a very well thought project.
What type of 3D scanner do you use?
It was always my goal to start drawing a K bike in 3D, but without a scanner this is nearly impossible.

What bar controls are you going to be using?

Thanks guys,

Work bought an Einscan Pro+ it's one of the less pricey scanners but it does an awesome job for this sort of work. The 3d printer really comes in handy and at the moment I'm only using an ebay one I think was $240 and is 220x220x260. But we also have one being put together that is 600x600x600mm which will be awesome. Yeah it's very handy especially just for making sure the parts will fit before I make them out of carbon fibre.

I'm not sure what bar controls I will be using yet however I will be getting the m.unit blue and the switches that match that. I have the full 2010 Yamaha R1 including the clip ons so I may just go with R1 controls if I can but I'm not sure yet.

Getting really close to finishing off the cad now. Just a few small tweaks to go. Ended up haveing to move the radiator fan to in front of the radiator so I will be making a shroud to disguise it a bit. Also eded up repainting the tank. It was too boring. I'll match the stripes when I make the carbon seat and maybe in the seet cushion as well... Got the chromoly coming so I can start on the new subframe too.