Suzuki GSX-R600 (& others) fuel tank pump blanking plate/flange

thingiverse

This is a useful plate for the K1 (2000-2001) Suzuki GSX-R600 fuel tank, perfect for those who want to remove rust from their tank. It fits in place of the fuel pump assembly, blocking the bottom of the fuel tank while you soak it in rust removers. I printed mine using a 0.8mm nozzle and 0.3mm layer height, with seven solid layers on the bottom (touching the seal) and five on top, and 30% infill from natural ABS. It spent two days soaking in sodium carbonate and water while undergoing electrolysis, followed by three days in five percent acidity vinegar in various positions, two more days in Hammerite rust remover, and finally experienced some Por-15 drips and vapors for another two days. It didn't warp or leak at all! The rusty droplet in the picture is from stagnant water on the outside of the seal - it's not a leak. This part was trickier to design than I expected because the holes aren't evenly spaced - they're designed this way to fit the fuel pump in one orientation only, aligning the fuel line with the injector rail when it's mounted on the bike. The arrow points towards the front of the bike. There's about 0.5mm wiggle room for shrinkage. The hardware required is five M6x20mm bolts. I imagine this plate would fit other Suzuki bikes too, like the GSX-R750 and GSX-R1000 (K1 & K2 models almost certainly), so feel free to try it out!