Hi guys. Sorry I've been away from this thread! I must have missed it.
Simon, they are older pics. I still do have the teardrop Targa mirrors on there.
Johan, I'm glad that you finally found some 954 forks! How is that coming along now?
To fit the 96-99 tank, I want to let you know that the mod you will do to your 93-95 frame will be irreversible!
Now let's get started...... you need to grind off the single post mount on the frame so that this section of the frame is completely flat. Then, take a flat piece of aluminum stock 5mm thick, by 1" wide x about 3.5" long. I don't know the exact length off the top of my head, but it is just a little bit narrower than the distance between the underside of the 96-99 front tank mount flange.
After sizing the plate, I used a Dremel sanding wheel to radius off the corners of the plate, then I used a lead pencil to mark the outline of the plate, making sure the plate was square and in line with the existing hole in the frame left over from the single hole mounting arrangement. I used the Dremel again to roughen up the underside of the plate, as well as the frame where the plate would go. I made sure the anodizing on the frame was removed in that part of the frame otherwise the JB Weld might not have adhered too well. But it is not critical as the bolts will tap through the plate and the frame which will lock it together. I erred on the safe side as I never wanted the plate to lift off!
I then used normal (not the 'Quik') JB-Weld to attach it to the frame, and waited overnight for it to dry. Next, I test fitted the tank (made sure the bottom mount under the seat was bolted in), put the mirror support and all the rubbers on too. When it was all centered, I used a metal punch to mark where the holes needed to be drilled. Removed all the hardware and drilled and tapped for an M6 thread. You have to take your time here to ensure that the hole is straight and perpendicular to the plate (don't just drill straight down from vertical!).
Test fitted it again including fitting the bolts till they were snug. Importantly, only use the factory steel bolts or equivalent stainless hex head bolts. Don't use those dressy anodized aluminum hex head bolts. They are not strong enough and will break off.
The next step is optional. When I was satisfied with the fit, I removed everything once more. I then took some JB Weld and with my fingertip, ran a bead around the plate and smoothed it into the frame. As I was powdercoating my frame, and JB Weld is fine for powdercoating, this made the plate look like it was a part of the headstem casting.
And there you have it. By the way, if you are going to retain your 93-95 gas petcock and fuel pump arrangement, you will also need to cut down the plastic fuel strainer. This is because the 96-99 tank is not as tall as the 93-95 tank. The strainer is a compression fit once you cut it down.