Kz1000 Carbon Fiber Fuel Tank

Thank you guys sooooo much for the support, and the offers to help. I may need to take some of you up on your offers :blush: I'm still searching for a filler neck, and the best fitting to use so a pingel petcock will screw right in. Tomorrow I want to try and get the parts cut out, new emblem inserts made and the mold prepped. I should have another top sometime this weekend.
ready2ryde, I emailed the company you linked to, this was my email:

I have a few questions regarding your carbon fiber tanks, and I was hoping you could help me out. I see you advertise a glossy finish, how is this achieved? What type of resin is used in the tank construction? I know that most epoxies do not contain UV inhibitors, so what are your recomendations to prevent yellowing of the resin? How many plys of material are used in construction, and what kind of material is used? Is the tank lined with anything, or is it raw? Lastly, I have heard from various people (usually ones that probably don't know what they're talking about) that fiberglass fuel tanks are illegal in some states. Do you know if this is true, and does it apply to carbon composites as well? I know, that's alot of questions, but $1K isn't exactly pocket change these days! Thanks for taking the time to help allay my fears, your tanks look soooooo coooool!

This was their response:

Hey adam,

We use a special epoxy resin in making our CF tanks. When the resin cures, it doesnt have that yellowish finish that regular fiberglass epoxy resin has. The reason why our CF tanks and other CF parts has that semi gloss finish its is because the top surface is coated with polyurethane. Yes there isnt any resin out there that protects the surface from UV rays that's why we coat the top surface with polyurethane. Our CF and fiberglass tanks has at least 3-4 layers on it and are 3/8" thick for safety reason. They are not light, but for safety reason, we have to make our tanks thick. Because of the ethanol mixed in regular pump gas, yes our CF tanks comes coated with a gas tank sealer. I think in some states you cant use fiberglass, CFs and even plastic tanks. But i have a 2008 ducati sport classic and it has a plastic gas tank that came from factory. I suggest that you call your local DMV and see if you could use other than metal tanks.


Most of his info is honest and correct, except his layers and tank thickness. 3-4 layers of carbon cloth is .035" - .05" thick (each layer of cloth is approx .011" thick) It takes ALOT of layers to get 3/8", soooooo I'm not sure what to make of that :dry:

To help remove entrapped air under the layers of cloth, I picked up these 2 rollers

the plastic one is a corner roller, and the aluminum one is a barrel roller. Most rollers are straight, but this one has a barrel shape to roll curves surfaces (like a fuel tank...) The epoxy is a clear formulation, and I hope the slow hardener will give me enough working time....it will be interesting

porchev914 wrote:

Thank you guys sooooo much for the support, and the offers to help. I may need to take some of you up on your offers :blush: I'm still searching for a filler neck, and the best fitting to use so a pingel petcock will screw right in. Tomorrow I want to try and get the parts cut out, new emblem inserts made and the mold prepped. I should have another top sometime this weekend.
ready2ryde, I emailed the company you linked to, this was my email:

I have a few questions regarding your carbon fiber tanks, and I was hoping you could help me out. I see you advertise a glossy finish, how is this achieved? What type of resin is used in the tank construction? I know that most epoxies do not contain UV inhibitors, so what are your recomendations to prevent yellowing of the resin? How many plys of material are used in construction, and what kind of material is used? Is the tank lined with anything, or is it raw? Lastly, I have heard from various people (usually ones that probably don't know what they're talking about) that fiberglass fuel tanks are illegal in some states. Do you know if this is true, and does it apply to carbon composites as well? I know, that's alot of questions, but $1K isn't exactly pocket change these days! Thanks for taking the time to help allay my fears, your tanks look soooooo coooool!

This was their response:

Hey adam,

We use a special epoxy resin in making our CF tanks. When the resin cures, it doesnt have that yellowish finish that regular fiberglass epoxy resin has. The reason why our CF tanks and other CF parts has that semi gloss finish its is because the top surface is coated with polyurethane. Yes there isnt any resin out there that protects the surface from UV rays that's why we coat the top surface with polyurethane. Our CF and fiberglass tanks has at least 3-4 layers on it and are 3/8" thick for safety reason. They are not light, but for safety reason, we have to make our tanks thick. Because of the ethanol mixed in regular pump gas, yes our CF tanks comes coated with a gas tank sealer. I think in some states you cant use fiberglass, CFs and even plastic tanks. But i have a 2008 ducati sport classic and it has a plastic gas tank that came from factory. I suggest that you call your local DMV and see if you could use other than metal tanks.


Most of his info is honest and correct, except his layers and tank thickness. 3-4 layers of carbon cloth is .035" - .05" thick (each layer of cloth is approx .011" thick) It takes ALOT of layers to get 3/8", soooooo I'm not sure what to make of that :dry:

Could they be double ply layers? That would equal 6-8 normal layers. I am wondering if they throw in a few fiber glass matt layers, as a space filler? Small boat makers use KV, CF & FG for their needed thickness. They also do it to cut down on the cost.

Nice to see Benjie back in the bike biz...and it looks like he jumped in with both feet with 3 offices world wide! Always loved his stuff.

Not a KZ but damn this this is nice!

I agree, Benjie has some nice lookin' stuff.

As far as his tank thickness and number of plys....he could very well be adding a TON of fiberglass between 3 or 4 layers of carbon. He didn't mention aramid, but aramid is just as expensive as carbon, so it's not a cost effective "filler". It's something you use when you need the properties of that material. There isn't anything like a "double ply" in carbon fabric that I am aware of. There is fabric that is much thicker/heavier, but it wouldn't easily conform to those tank dimensions....I don't think. Even if it did, it would still take more than 3-4 layers. So yeah, he must be using a truck load of fiberglass to get that kind of tank thickness. It would definately be strong and damage resistant!

This one is resin injected, but it has thickness.

This one is a cheap boat ad, but they got a lot of thickness.

Sorry Adam!

Wasn't trying to Jack your thread! I was getting bored, waiting...hahaha!.....Your doing Good, Good Job! Sorry I don't have a Popcorn Dude.

Just one more on the basic process. I'm still trying to get my head, wrapped around this. Good thing your walking us through it.

Well thank you for the youtube videos kzz1p. I hadn't seen the first 2, but I have seen the third. As for the thickness of the boats, the first vid did not have a very thick hull. He did say there was 30 pieces of fabric, but many of those were partial pieces to reinforce certain sections of the design. I did learn there are double ply aramid fabrics available somewhere! The good dog boat though, it has thickness because of core material. I was planning to incorporate some core material in the next tank top, and reduce the # of plys. That way I can get the thickness over the body of the tank for rigidity and strength while affording a lighter weight. 3.396 lbs is light for an unfinished tank, but I think I can make it just as strong with a little less weight. I'd be happy with 3 lbs even.....yeah, that and a defect free finish! :laugh: :laugh:

I sanded the right side of the tank with 1500 grit and a quick polish with a buffer. WOW what a difference. Now it looks GOOD! At least the spots without the bubbles do :blush: enjoy

And enjoy some more :woohoo:

oh man!!!!........ that is spectacular