21 replies to this topic

[SquirrelTurds]

First let me get this off my chest. If you don't like my welds ... well neither do I! That is why I weld as a hobby!
Also If you don't like how low the tank hangs then I hope you have a pathfinder and your jumping dunes every weekend. In that case I would suggest the 19gal tank!

Whew I'm glad that's over! NOW you have 3 options. EVERY tank is made the EXACT SAME, all you have to decide is how low you want yours to hang. I decided to go with the 38gal tanks (F36B) but you also could go with the 19gal (F1B), or better yet the 22Gal (F15B). I am willing to bet with the 22 gal you would not even have to modify the tank straps.

Here starts the side by side comparisons. After that is step by step instructions.

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[SquirrelTurds]

First Thing to do is relocate the inlet and vent tube. I did this with a angle grinder and dremmel (for curved parts). Remember there is NOTHING a ball peen hammer can do! Once I had the corner cut out I just started hammering the metal to curve it to the corner. Then I test fit it to make sure that the tube lined up to the fuel spout. This tank has a good 4 inches of gap IF you modify the straps. (more to come on the straps)

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[SquirrelTurds]

Next is the modification to the top supports. These pictures will be of JUST the 2 supports nearest to the axle. I cut them out and then took about 1inch off of the top clearance and about 4 inches off of the cross member clearance. Then tape them to the tank and tack weld in place.

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[SquirrelTurds]

For the rear supports I cut out a section that was about the size of a quarter. It was right at the curve. Also notice the red arrow that points to the section of frame that I had to cut out for the lip of the tank.

The next photos are the modifications to the straps. Very simple: put the tank up, cut the straps in half and mark where they come to. After that get some raw metal and make a "filler" strap.

I also noticed that my filler tube had some small pin holes. I welded those up, only to find the breather vent was beyond repair. I cut the breather vent with just enough space to attach a rubber hose. I then powdercoated the straps and filler tube. Since powdercoating is fuel resistant it should cover up the microscopic rust holes that I could not see!

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[SquirrelTurds]

Next is to modify the sending unit. Because the one you have to buy is for the 19gal tank. Here is a link to the thread for the sending unit. The modification to the sending unit is not easy! I hope your good a sweatin pipe!

After that I cut the control valve seat out of the old tank.

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[SquirrelTurds]

Lastly Weld the control valve seat into place on the new tank, and then check the tank for leaks. (leaks continues on the next post)

I also welded a tab of metal to make sure that the strap would not slip off of the tank. Once I knew the tank did not have any leaks I hit all of my welds with bed line so that they would not rust.

As you can see the finish product does not hang as low as I expected. I am very happy with it.

As for the vent tube on the tank and filler neck. One is 3/4 and one is 3/8. So I went to a local pipe company and they supplied me with the tools to connect the two! FYI the all of the tubing was about 100 bucks

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[SquirrelTurds]

I left this picture as a big one to show how I did my pressure check. I attached the sending unit to the control valve and then covered up the inlet tube. Put the air hose in and then I sprayed soapy water on my welds. I had about 8 leaks. one of which was around the inlet tube. When I was welding the metal got so hot the silver around the inlet tube melted away. Nothing that a blow torch and some more silver couldn't solve!

(Roger I hope I didn't use up to much memory, I tried to keep the photos small!)

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[Tom Snyder]

SquirrelTurds said:

(Roger I hope I didn't use up to much memory, I tried to keep the photos small!)

Use Photobucket & don’t worry about it! It’s free & easy to use.
See post #3 & follow the link to my other posts too.
http://econolines.ip...104
More info.
‘Tips & Tricks’, ‘Posting Pictures’ post #16.
http://econolines.ip...608

I just posted that last one today. Squirrel, try to keep up with the old fart, will ya.

"Keeping up the easy way”
http://econolines.ip...?showtopic=4782

[Roger]

Nice job Squirrel!.. And don't worry about using up space. This type of stuff is definitely worth it.

[Mat Mobile]

Nice job. This the first time I see someone doing this upgrade.

To be honest, since you said that all tanks were the same... I didn't expect so many modifications.

[SquirrelTurds]

Mat Mobile, on 13 April 2011 - 05:30 PM, said:

Nice job. This the first time I see someone doing this upgrade.

To be honest, since you said that all tanks were the same... I didn't expect so many modifications.

All of the tanks are the same, as in they are made for the 2nd gen F100 and 3rd gen E100 (and many others). NO ONE makes tanks for the 2nd gen E***'s and that is why there are so many modifications!

[Mat Mobile]

SquirrelTurds, on 13 April 2011 - 06:15 PM, said:

Mat Mobile, on 13 April 2011 - 05:30 PM, said:

Nice job. This the first time I see someone doing this upgrade.

To be honest, since you said that all tanks were the same... I didn't expect so many modifications.

All of the tanks are the same, as in they are made for the 2nd gen F100 and 3rd gen E100 (and many others). NO ONE makes tanks for the 2nd gen E***'s and that is why there are so many modifications!

Ok, now I understand...

[SquirrelTurds]

Poured gas into her and fired her up today. Found a kink in the line, but after that she purred like a kitten! The gas needle even started to move after the first 1/2 a gallon! I am very pleased with myself!

[Roger]

Sweet!.. Have you filled the tank yet?. Just wondering if it's accurate when full too.

[SquirrelTurds]

Roger, on 20 April 2011 - 02:45 PM, said:

Sweet!.. Have you filled the tank yet?. Just wondering if it's accurate when full too.

I already know it will not be accurate when full. EVEN the diagram on extending the sending unit makes it read full at half a tank. The important part is that it read E and then after putting in 1 1/2 gallons it started to come up off E!!!! So long as I know E MEANS E I'm happy. My guess is that it will read F at about 19 of the 38 gallons.

I really did not have the time to manufacture an arm that would do the full sweep!