SuzukiSavage.com - Fuel Tank Cushion Mounts

Gary_in_NJ

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Fuel Tank Cushion Mounts
05/25/17 at 10:11:19

As part of my DRZ Tracker project I have to remove the existing mount "ears" on the front of the fuel tank and weld on some new ones (lower and towards the center of the tank). These things seem to be shaped just right to capture the cushions. I was hoping someone on ebay was selling these but couldn't find them. Has anyone fabricated these and if so, what did you use as a template?

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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2772	Re: Fuel Tank Cushion Mounts Reply #1 - 05/25/17 at 10:50:19 You are not able to simply move the mount to work with the tank? I had to move my mount forward and up to work with the GT185 tank. It's up towards the headtube.
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2772	Re: Fuel Tank Cushion Mounts Reply #2 - 05/25/17 at 10:51:04 I found your post about replacing the radiators with a single unit. This should leave you with plenty of real estate up near the head tube. I would think you could put your mount in that area and not get into mucking around with that super nice tank you got. Otherwise, all I have to offer is that cardboard is your friend.
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Gary_in_NJ

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Re: Fuel Tank Cushion Mounts
Reply #3 - 05/25/17 at 11:07:11

The existing cushion holders on the tank have to be removed to clear the frame down-tube and an oil breather line that runs along side of it. It's a very tight fit. The frame can't be modified in this location because it also serves as the oil tank. There are existing frame mounts to accept the cushions on the frame, but in fitting the tank they will be at the very lower edge of the tank. The tank is 21 inches long and the mounts land around 10 inches from the front of the tank. I will be able to weld in a forward locking mount to run a bolt through as well as the rear mount, so the tank will be well supported.

My concern is that I wont get the shape of the cushion receiver correct and it will be a sloppy fit. I wish I could un-weld the original.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Fuel Tank Cushion Mounts Reply #4 - 05/25/17 at 11:33:38 Gary: I removed my bogus post.....maybe I will do better this time. How expensive/easy is it to find another tank? You could cut the tank mounts out of a donor tank, then carefully remove the tank metal from the stock mounts....then weld them onto the tank you are keeping.
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Gary_in_NJ

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Re: Fuel Tank Cushion Mounts
Reply #5 - 05/25/17 at 11:39:29

The tank I have is pristine. NOS from 1977 - has never seen fuel. It's getting used.

I could look for a crushed tank and cut out what I need. That's a good idea. My buddy that will be doing the welding will be by this weekend. I'll ask him if he thinks he can faithfully recreate the original tabs. If not I'll get a donor tank. Good idea.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Fuel Tank Cushion Mounts Reply #6 - 05/25/17 at 11:43:27 Wow...that is a nice tank. Snappy color too!
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ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2772	Re: Fuel Tank Cushion Mounts Reply #7 - 05/25/17 at 11:49:05 Bummer that you have to weld on that tank, but I guess you have to do it. Here's the original build thread for anyone who's interested. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1484061156/15
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stewmills

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Re: Fuel Tank Cushion Mounts
Reply #8 - 05/25/17 at 12:06:24

You don't think there is an epoxy (or something like JB Weld) that would suffice instead of actually having to weld on the tank? Whether or not you would need to strip the paint from that area may be debatable for good adhesion, but at least you wouldn't risk creating a hole or warping or marring that beautiful paint from overheating or sparks.

Good luck.

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Fuel Tank Cushion Mounts Reply #9 - 05/25/17 at 12:07:26 Here are the tabs I need. This is not my tank, but a GS tank (same cushions) on ebay for $38 shipped.
Back to top	Cushion_Mounts.jpg A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged

ohiomoto

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Re: Fuel Tank Cushion Mounts
Reply #10 - 05/25/17 at 12:16:59

Given the time and expense to get the tank and remove the mounts, I would just fab them up. Just bend a piece of sheet metal over a similar sized piece of round stock, cut two slices off and weld them one.

If you do get that tank, get your self a spot weld cutter: https://www.harborfreight.com/3-8-eighth-inch-double-sided-rotary-spot-weld-c...

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Fuel Tank Cushion Mounts Reply #11 - 05/25/17 at 13:12:28 If anyone has a Savage tank that is garbage, let me know. I think the brackets I'm looking for are the same.
Back to top	A life-time student of motorcycling. LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS My LS650=> http://suzukisavage.com/yabb2.2/Attachments/Left.JPG IP Logged

Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Fuel Tank Cushion Mounts Reply #12 - 05/26/17 at 02:44:23 Gary: I have a TS90 tank I will be cutting up....I will look and see what those mounts look like. Dave
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Gary_in_NJ

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Re: Fuel Tank Cushion Mounts
Reply #13 - 05/26/17 at 05:29:51

After doing some more fitting work and taking measurements, I can't use cushions at all. This tank is gonna be a tight squeeze.

I'm gonna have to weld a bolt on the top of the frame and weld a strip of metal to the tank to connect/secure the tank to the frame.

There are cushion mounts on the DRZ frame that line-up perfectly with the bottom of the tank, but unfortunately the mounts are 3.6" wide and the tank is only 3.2" wide in that location. I'm gonna have to remove the frame mounts just to slide the tank in position.

Oh, the fuel petcock is gonna interfere with part of the frame...but I think a Raptor will do the trick...

Making this tank fit is a wee bit more work then I thought - but it will get done.

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A life-time student of motorcycling.
LS650 Cafe, DRZ400SM, FZ6N, SV650S, CB900C, Ducati ST2, CB550F-SS
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2633 Amongst the Twisty Roads	Re: Fuel Tank Cushion Mounts Reply #14 - 05/26/17 at 19:13:04 I got this sorted out. Check my build thread for the solution. Thanks for the help and support. That one had me stumped for a few days.
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