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FJR Motorcycle Forums
FJR Parts & Accessories Discussions
Auxiliary Cell Design
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<blockquote data-quote="Checkswrecks" data-source="post: 336410" data-attributes="member: 3536"><p>Pretty cool, but a couple of thoughts:</p><p></p><p>1. Fatigue is the enemy of sheetmetal. The fatigue crack in this design will form where the curved surface is welded to the flat surface. Try real hard to avoid welds in general and especially at right angles to a big flat surface like that. Suggestion #1: Make the top, front, two sides, and rear of one piece with gentle bends (CAD is a great resource to get the vertical corners right), then weld on the bottom. Suggestion #2: Make the entire Z-shaped bottom of a single piece. Give it a good half-inch or more of bend radius where your current sketch shows the bottom and top of the curved part.</p><p></p><p>2. Sheetmetal tanks are commonly held down by straps, because people long ago realized that cracks form at the edges of mounting tabs or where the wall thickness changes abruptly. Think carefully about how you'll hold the tank down. Also think about fatigue in terms of any tabs for light brackets, cargo tie-downs, etc.</p><p></p><p>3. Explosafe or any of the other foams are generally well-recognized as baffle material, but you'll need to check the IBA rulebook to make sure.</p><p></p><p>Hope this helps.</p><p></p><p>Bob</p></blockquote><p></p>
[QUOTE="Checkswrecks, post: 336410, member: 3536"] Pretty cool, but a couple of thoughts: 1. Fatigue is the enemy of sheetmetal. The fatigue crack in this design will form where the curved surface is welded to the flat surface. Try real hard to avoid welds in general and especially at right angles to a big flat surface like that. Suggestion #1: Make the top, front, two sides, and rear of one piece with gentle bends (CAD is a great resource to get the vertical corners right), then weld on the bottom. Suggestion #2: Make the entire Z-shaped bottom of a single piece. Give it a good half-inch or more of bend radius where your current sketch shows the bottom and top of the curved part. 2. Sheetmetal tanks are commonly held down by straps, because people long ago realized that cracks form at the edges of mounting tabs or where the wall thickness changes abruptly. Think carefully about how you'll hold the tank down. Also think about fatigue in terms of any tabs for light brackets, cargo tie-downs, etc. 3. Explosafe or any of the other foams are generally well-recognized as baffle material, but you'll need to check the IBA rulebook to make sure. Hope this helps. Bob [/QUOTE]
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