Half the Weight, Twice as Cool: Ducati 916 Replica Tank

Lightweight, Aluminum, and Fuel-Proof: Next-Level 916 Replica Tanks from ETTO Motorcycles… 

In 1994, the boys from Bologna unveiled a new superbike destined to become a motoring icon: the Ducati 916. Massimo Tamburini was instrumental in developing the bike’s water-cooled four-valve desmodromic 90º V-twin. The engine made less outright power (114 bhp) than many of the Japanese inline fours but boasted a much wider torque spread, which translated incredibly well to both the road and track.

The 916 remains one of motorcycling’s most striking fusions of function and form. The single-sided swingarm allowed for faster wheel changes during races, the underseat exhaust made the bike more aerodynamic, and the narrow waist and slit-eye headlights helped make the 916 one of the most beautiful superbikes ever created, even to this day.

Then there was the 916’s prowess on the racetrack. Ducati won a string of World Superbike Manufacturer’s Championships with the 916, mostly with the legendary Carl Fogarty piloting the bike. What’s more, the 916’s close derivatives — the 748, 996, and 998 — continued the brand’s winning streak. Even the Japanese began to flirt with V-twin superbikes.

“The Ducati 916 managed to achieve something very few other bikes have ever managed – it transcended the boundaries of the market and gained universal recognition and praise from both motorcyclists and non-motorcyclists alike.” –MCN

The swooping, sculpted fuel tank is central to the definitive style of the 916. However, age and ethanol have been conspiring to corrode the steel originals from the inside out. That’s where our friend Ian Davis, the UK-based metal master behind ETTO Motorcycles, saw an opportunity to offer a lightweight, fuel-proof aluminum alternative. 

“Over here in the UK, the 916 is held in high regard. Carl Fogarty, four-time WSB Champion, set an attendance record back in 1999 when 120,000 fans watched him take his fourth title at Brands Hatch GP circuit on a 996.”

At a featherlight 2.15 kg, the ETTO tank is almost half the weight of the 4.19-kg original. As well as being lighter and ethanol-proof, ETTO’s offering is the most accurate reproduction to date, the result of almost two years spent prototyping, tooling, and refining details.

The ETTO tank replicates the 15-inch wide upgraded unit Ducati developed after fitting a 16-inch unit to the earliest bikes. The ETTO tank also fits bikes that originally came with the wider tank.

The ETTO offering is not the first aluminum tank to be developed for the 916 series. However, it can claim to be the most accurate with numerous features unique to ETTO. This is the first aluminum replica tank with a two-piece base.

Complex tooling was developed so that 1.5mm thick 1050 aluminum could be drawn down to maintain its thickness during pressing. A two-piece base also ensures strength, reduces the zone affected by welding heat, and contributes to weight savings.

The entire top and sides are made from just two pieces. Again, huge effort was expended to create the dies for these sections. Incredibly, only one weld is used to join them, minimizing the heat affected zone. ETTO opted for a gas weld here, malleable enough to be planished on the English wheel. The result is an exceptional looking tank with few welds. To ensure accuracy of detail, the entire seam has been tipped to replicate the original tank.

The fuel pump is notoriously difficult to remove and refit on previously available replica tanks. The ETTO tank has a chamfered pump ring with stainless steel inserts to avoid damage to the aluminum ring when the pump is withdrawn. The blind threaded bosses have been recessed, as per the original tank, so the OEM bolts can be used.

ETTO has also included a drain plug boss. As with the pump ring, threaded bosses, breather tube, and second skin for the TIG-welded rear bracket, the boss is aluminum brazed in place.

Although super-strong, aluminum brazing is a notoriously tricky technique. Its difficulty is compounded when dealing with parts of different thicknesses and hence variable heat retention. ETTO rose to this challenge and others to realize the vision of the finest replica tank yet.

The first batch of four tanks are available now. Price is £2250 including Newton cap and Ariete breather. These fit all models of the 916 series. Contact ETTO Motorcycles here or by any of the means below to order.

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