This is the process of getting ROO my 1400GTR up to spec for bigger rides here but mainly for the 2009 Iron Butt Rally in the US.

I got the fuel tank, its a 5 gal (19litre) JAZ tank 547-250-005-01

After finding a local company prepared to have a go at making the support brackets he finished a masterpiece of mostly my design. I say mostly because I came up with what I wanted and how it would be supported and connected but he did it better than just a piece of alum plate I had in mind.

This is the rear section which holds the Givi V46 top box, it must be further back to allow fitting of the 13" x 13" x 8" tank in front. It can be pulled apart in two sections when finished so I can get the tank off and gain access to the under seat area if needed. The rear extends 90mm longer than stock bike length. This is important because GetRouted who are shipping it to the US next year for me have a max length of 2300mm. So that puts Roo at 2360, too long. So the rear section unbolts within 10mins tops bringing it back to the stock length of 2270mm.

So far, being modeled here by RUKU while ROO sits in the garage.

Completed and moved onto my own bike Roo

Some closer images of the tank on the brackets

Bulkhead fitted to the main tank.

Overflow out the rear

More images

Overflow has been replaced with regular fuel hose and exited out the other side, plus wire connected to the tank as an earth strap attached to one of the 6 bolts in the filler and under the tank cover to a good earth.

I have since altered the overflow fitting into the tank and shortened the drop inside, this enables me to fit 18.5 litres while on the side stand. I have also removed the braided overflow line and replaced it with rubber fuel hose and included a quick release behind the pannier on it so the hose extending out the rear can stay in place when the tank is removed. I have managed 700-730klms per fill this way.