I've fabricated a new gas tank and its mounting. The tank is a little 2.5gallon HDPE plastic tank, it weighs almost nothing.
This car better get at least 60mpg to make a 120mile trip.
I removed the fuel pump and sender assembly from the metro tank,
cut out the mounting boss from the tank, and sandwiched it between the HDPE to seal it off. Also had to seal up a cut-off part of the tank, and learned that the only way to seal HDPE is to "weld" it by just melting it together, worked great with the heat gun, I was impressed it worked so well. Of course, then something else took forever... I had to modify the pump bracket so it reached the bottom of the tank, and completely redo/reposition the sending unit so it would privot inside the small tank and register F-E. It seemed to be corroded too, so I spent hours getting the potentiometer to work like it was suppose to.
I relocated the tank to ahead of the rear axle, and had to fabricate a box to hold it and protect it. I had torn apart a refridergator to get the compressor to make a kegerator for my patio, and the old enamel sheetmetal came in handy, as I've not had time to take it to recycling yet. Good reinforced construction.
I still need to run the lines and the filler tube. I got some 1/4 PEX tubing to run the fuel lines, light stuff, and just like the tank, want to avoid steel or aluminum in case of E85. Any suggestions on the fittings? Nylon?
