Jaxon at Ride On ADV does a better job on his expanded tanks than mine. His are more oem looking with smoother transitions and angles. But I couldn't afford his pricing, so found a local welder that was willing to take on the job. No issues at all with the tank. No leaks, no changes, zero problems. It's very well done, if not esthetically pleasing to some eyes.
FWIW, generators run under a unique set of parameters, long periods of steady state rpms with the same harmonic vibration level the entire time they run under load. Motorcycles vary rpm much more and the vibrations change rather than humming at the same frequency. I think this is why I've never seen an expanded tank split at a weld, (or a fuel cell), and I know of hundreds in use.
For riders that do endurance rallies and long distance riding on a regular basis, or enjoy traveling in far off the beaten path locations, a larger tank or fuel cell plumbed into the system is very useful. Sometimes it's not about where you can get gas, but when. Lots of tiny towns don't have 24 hour pumps. Oregon still only allows self serve gas pumping in rural counties under 40,000 residents. This is good for Eastern Oregon where most areas qualify. New Jersey apparently still doesn't allow self serve either, though I thought they changed that a few years back.
Endurance riding or Long Distance riding on a regular basis means learning and changing the ergonomics of your bike so it's not torture. My Super Ten is a barkolounger on wheels. Far more comfortable than my truck for long distances. That is a process. You fix the things that bother you until there are no things that bother you as you ride longer periods of time and miles.
As far as your opinion, you are very welcome to enjoy riding like you do. But others enjoy different riding, and they aren't torturing themselves. I actually do have a 10/10ths cert. And 5k in 5 days, and have done a 10 day rally where I rode over 12k miles and a 11 day rally where I rode just under 10k miles. I've ridden many more endurance rallies of 8 to 36 hours and other multi day rallies as well. The actual rally mileage doesn't really paint the full picture though. Often the rally was thousands of miles from my home. I rode from Portland, OR to Hot Springs, AR to ride in a 24 hour rally that I only ride 500 miles during the rally, (3rd place!). So I rode over 5k miles in about 7 days just getting there, doing the rally and getting home. On the 10 day rally I wore out a brand new set of tires in 14 days. You should have seen the dealers face when I walked in needing a new set of tires mounted. He asked what was wrong with the set I just had mounted. "nothing, just wore them out" says I. Into the cords with 14k+ on that set of Avons.
The point is that some riders are set up to enjoy doing lots of long days, back to back to back. What may have been torture for you is nothing for me. I have often ridden tank to tank over and over w/o putting a foot down. Rally riding isn't like that, you cover lots of miles but are stopped and/or off the bike to get bonuses, thought briefly. Just touring I used to commonly ride 500 miles w/o putting a foot down. That's less than 8 hours sometimes. I've ridden 20 hours a day, off the bike for 4 hours, slept for a solid 3 hours, (I sleep in 3 hour cycles, from rem to D state and back thru rem), then back on the road for another 20 hour day. And I did that for over a week strait w/o issues.
Sorry for the highjack. Bigger tanks meet a need. It's not always constant riding, it's about having gas in the middle of no-where or not having to worry about having enough gas to get back out of some place you want to explore where there are no services. Or riding thru the night in a large Western state that doesn't have 24 hour gas. Or simply stopping when you WANT to stop, instead of when you HAVE to stop.
In my case, the expanded tank is actually less fuel than I was carrying before I installed it. It's about matching the range of my favorite riding partner. Just a convenience thing. Now I have a solid 300 mile range with reserve for another 40-50 miles if I need it. Before I had 450 miles + reserve on the Super Ten. (I guess I'm getting old and slowing down
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