6 monthly progress report... here are how things are going. I've got all the bits together, kind of. The tank is work in progress - 2mm alloy cut out, shaped and tack welded together. It needs a bit of fettling before getting the seams fully welded. The rear guard is loosely in place, as are the side panels. The frame needs a couple more lugs welded to take the tank and CDI and skidplate, then powder coating in Kawasaki green. Then comes the scary part - finding out how this thing handles...

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A few more pics

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Man, that's looking really sharp! What frame are you using there?

Nice tank on there. Did the stock one not fit with the pipe? Would it work with the pipe cut and moved? Just hoping you don't dent the tank, its too nice to ever lay the bike over.

Thanks for the feedback.

The frame is a 1986 KX125, the first of the modern rear linkage style and rear disc brake. The year later they went to a twin down tube to accommodate the centre exhaust port. So this is the latest 125 frame you can drop the C series 200 motor into.

Because the subframe, airbox and seat is from an 89 KX, there was less space between the headstock and the seat, which meant that a tank had to be built to fit. Also the larger aftermarket triple clamps come back further on full lock.

I try not to think about denting the tank
I tried to keep it slim as possible in case.

that is some great handy work. very nice

hi there, do you foresee any problems with the pipe being so close to the alloy tank in regards to fuel getting hot in the tank? just a thought from looking at the pics. very nice work tho, the whole bike looks very sharp!

Thanks. Yep, the tank runs close to the pipe, there's about a 2mm gap at the closest point, and 5mm + for the most part. I was hoping this wouldn't be a problem as the temperature of a 2 stroke expansion pipe isn't excessive, and it should get good air flow. It would be good to get opinions on this. I haven't drilled the mounting holes into the tank flanges yet, so could always mount it a bit higher to increase the gap.

Very nice work Arjay! I really like where you are going with this. I would sure hate the 2mm clearance being too tight, you matched the angles so nice between the triple clamps and pipe, I am pretty sure I have seen tighter? I am thinking along the same lines with my rm370. And am really liking the idea of the shrouds directing air atop the motor. Hopefully I will not have to make a new tank! But, now I may know a guy?