Ok some details about the mounts.
I started with 7/16" bolts and 1-1/4" angle (0.112" thick) shown below. The silver cylinders I spun up on the lathe to fit the yamaha tank rubbers.
My plan was to use the holes that are located on each side of the frame that come stock with a small plastic plug in them. See the hole by the yellow arrow below. These holes can be drilled out for a 6mm thru bolt. I actually tapped them for 6mm first for temporary mount work but the wall is too thin for that to ever to be tightened down.
Then I added flats and cut the bolts to length.
I needed to look for a hole that was lower for the second mount hole. On the left side the rear horn mount is a perfect location. The right side does NOT have a matching hole.
I set the tank in place held up where I wanted it with shims. From here I put the posts in place with the aluminum cylinders and tank rubbers but without the angle plates. Once I had them aligned, I clamped the angle plates in place and marked one for post location and from there struck the side angles. I angled the one edge of the angle plates. and now they are ready for welding.
Once I had them welded up I taped the frame and struck lines so I knew the centers of the holes but out beyond the angle plates so I could see where things would line up. I located the holes on one plate and drilled both of them together so they matched.
Here is how the left side fits. Note the horn is hanging just out of the left side of the picture. The open hole showing in the pic is the second horn mount that I won't be using for the tank. the tank has just enough width that I can still put the horn back in place once I make a shim the same thickness as the tank mount.
From there I clamped a straight piece to my bolts so I had everything in full alignment. I then center punched that lower hole so I could drill the one new hole in the frame to match with the horn mount hole on the other side.
Now the plan is that I will use 6mm thru bolts with nuts to hold the mounts. I will insert them from the left so the lower one pulls the internal nut on the horn mount towards the frame wall and not off it. I will tighten that one and then nut the right side on both of them. I still need to do some shaping to the angle plates so they look nicer.
The threaded section of the bolts with the aluminum cylinders allow me to dial in the width of the mount. All of it will be painted black when it is done.
What I really like about this mount is it only needs one new 6mm hole in the frame and it does not interfere with any of the solenoids or relays under the tank. Nothing had to be relocated.
As far as the rear mount for that I wanted something adjustable so I could get it placed right. I went with the stock rubber pad and mounting from the Vstar and made an aluminum angle that you can see in the pictures below. They have an inverted U shape piece that the aluminum replaces.
For the lower half then I went with an angle again this time 3/16" thick. and replaced the rubber stock S-40 mounts with aluminum spacers. I slotted the angle so it could be slid forward or back to match the tank during bolt up. I went with 3/16" so I could tap holes and have enough threads that I don't need nuts up under the tank.
Here it is on the frame
Here it is looking under the tank to see the two bolts I put in to secure the back of the tank.
I plan to trim up the aluminum angle because right now I have it trapped between the aluminum spacers and the angle. I want just a little more rearward adjustment out of it.
Here is a pic with the aluminum piece in place but the tank removed.
Now you could look at that and say why didn't you just make one Z shaped piece and be done? The answer? now I could but there were two reasons I didn't. When I was working through this I wanted to be able to fit and adjust and align things the way I wanted and needed to get the right fit. Secondly that then forces you to remove the two bolts that hold the seat tang catch each time you want to remove the tank just like you do today on the S-40. That was actually my original plan but I realized it would be a pain working with those as they were tucked under the tank and you could only get a wrench in there and not a ratchet and you would have limited height above the bolts. (see the under tank pic above). I found it easier to install and remove the two bolts as shown above that hold the aluminum angle to the steel.
The process then becomes to bolt the aluminum piece to the tank with the rubber mounts and that is one unit. Place the tank on the front mounts and drop the rear down just as you do on an S-40. Have the rear mount in place but loose so that you can slide the steel angle forward or back to meet the aluminum angle. (note the slots in the steel angle). Then put the two bolts in that hold the aluminum plate to the steel and tighten them up and then tighten the two bolts that hold the seat tang catch. That locates the steel angle correctly and you never need to adjust it. Now it becomes just the two bolts that hold the aluminum angle to to the steel that ever get removed for tank removal.
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