Yea. I agree. It is a lot of work, but so is the amount of work rebuilding all the infrastructure to hold the tank, remounting the oil filter hidden underneath, etc, etc. The tank in question has some pretty unique mounting (isolastic-style dampers) to which I adapted the frame, so it's a hornet's nest of problems to dig into. My carbs clear, my cables clear, my hoses clear, my electrical clears, so that's the size and shape I'm going with!
I also want to build an Elephant Foot tank, make a mold for an early 50s manx seat, and a primary belt cover is mostly done, so it's just another thing to do really. Fiberglass is pretty fun and suits my brain's idiosyncrasies, and building things is a compulsion I've yet been able to get under control. What do ya do?
The tank is 100% rubber mounted and doesn't touch a single item that is not rubber, nor is it held down tightly. It has failed in the past and will continue to fail with the fatigue of being surrounded by a heavily vibrating motorcycle while filled with thick vibration damping oil. All its fractures have been along the bottom seam, not where it mounts at the top. The welding repairs just exacerbates the weakening of the aluminum. I've got around 7000 miles on the tank (much more than your average race bike after as many years), so I think it's time to go. I have not raced though, so what do I know?
I'll be making some parts for myself, but the oil tanks will be pretty time consumptive, so pretty expensive if I choose to make and sell any more. It will need to be a three part mold, leading to a clamshell to be bonded shut, all with custom made bungs for the plumbing and mounting. Anything I make will be fiberglass and not carbon fiber. Carbon fiber is horrendously abrasive, and not so good for breathing. I've done projects with it in the past, and I'm definitely over it. It's a lung and tool killer.
The oil filter bolt is 1"-20 UNEF, by the way. The tap on its way, and the plug is mostly done. Too late to turn back now...
Should I post progress?