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Engineering 2.0

After safety testing, the decision was made to go with a polycarbonate fuel container. You either need a vacuum former big enough to make it from solid poly sheets, or come up with a way to assemble flat sheets in to a round shape.

Everything had to be assembled without glue, in order to be able to repair each individual part if necessary.
Simple wooden strips are cut and bend with steam to hold the poly sheets in place.
Big, custom steel clamps are used to keep the wooden strips together after bending. Steel wire and tensioners are used to make sure the whole assembly stays together. Each strip has 2 threaded mounting points to mount the tank to a steel frame on the motorcycle.

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