fuel tank

[jackboeker83]

I have the fuel tank that comes with the complete kit and I am having a problem getting it to fit. The fuel tank strap on the passenger side doesn't seem to want to fit and also the fuel fill neck is hitting the frame. Has anyone had this problem and if so what did you do to fix it.

PS- I did bend the ends of the gas tank flat... thanks to lazrcng

[edwardb]

Fuel fill neck hitting the frame is apparently not an uncommon problem. Happened on my Mk4 build as well. First make sure you have the supplied bumpers in the ends of the 3/4 tubes that contact the edge of the tank. If those are there, and you still have interference, you have two choices. "Clearance" the frame with a hammer (or whatever) or lower the tank slightly. I opted for the latter. I made some small bumpers by cutting up a large hard rubber stopper from the local Ace hardware. They only need to be about 1/4 in. thick, and I put a radius on them so they fit nicely into the lip of the tank. I glued them onto the supplied bumpers with some thick instant glue. Once the tank is in place, they're not going anywhere. I read on here about one guy that made some bumpers from a hockey puck. But lower it slightly and see if that does it.

Not sure I understand the other problem. Install the horizontal back bolt first, with the strap pivoting under the tank. They pull the strap into position and install/tighten the front vertical bolt. Maybe what you're describing is you can't get the front bolt to start? Some (including me) replaced the supplied bolt with a lightly longer one because it was really hard to get the one provided to start. Especially if you lower the tank slightly. But once you get the threads started, it will pull down quite a bit.

BTW, installing the tank and straps, especially with only one person, can be challenging. Not enough hands. I put a piece of plywood about 2 x 2 and a blanket on a floor jack and used to lift the tank into place. Positioned it where it needed to be tight against the bumpers, and then had both hands free to install the straps. Pretty easy that way.

[MPTech]

I picked up some bumpers (square tubing plugs) from the Sears Hardware store. They were in the specialty parts area in the plastic bins/trays. They had to be trimmed just a little.
BEFORE you install the tank, did you figure out what you're going to do for the rear bumper bolts and the smaller latch bolt.
If you don't do them first, you'll have to drop the tank again.


http://www.ffcars.com/forums/17-factory-five-roadsters/287406-rear-bumper-bolts-mod.html


http://www.ffcars.com/forums/17-factory-five-roadsters/295594-rear-body-mount-bolts.html

[Avalanche325]

Get a longer bolt, or you may loose your sanity.

I did the same as edwardb. I got some rubber bumpers and bolted them on to the plastic plugs and popped them back in. It gives just enough clearance.

[montyals]

One of the tank straps will be hard to secure if you tighten the other one all the way. You have to get the straps and the bolts secured by only one or two threads, barely enough to hold the straps in place, before you connect the other one. Once both are barely hanging on then you can go ahead and tighten them. I've done it a few times and you'd swear you're going crazy cause you know it was secured before. The fuel neck filler just requires A LOT of patience and some fidgeting.