Fuel System - Tank installation clearance issue

Hello everyone,

Yet another issue thread regarding the installation of the fuel tank. As I always do before posting, I've searched through the forum and have found many to have similar problems (almost identical to this one: https://thefactoryfiveforum.com/show...s-Tank-install), however, the solutions I've found are not working for me.

The vertical 3 x 4'' mounting tubes are not cooperating, specifically the ones on the passenger side. I've tried moving the front one with a dead-blow hammer to no avail. I've had to use ratchet straps but as soon as I release the tension, the vertical tube snaps back. I need to move it a hair over 3/8'' in order for the fuel tank to fit.

Front mounting tube at rest
Attachment 175870

Front mounting tube in tension
Attachment 175871


I'm already uncomfortable with the amount of scrapping from trying to get it to fit. In fact, does it look like the fuel tank was knicked?

Front scrapes
Attachment 175872

Rear scrapes
Attachment 175873

The solution I'm seeing is to mount the tank with the strap in place get the clearance, and then wrap the bottom for the 3 x 4'' front and rear mounting tubes with weatherstrip for cushioning and protection and then release the ratchet. It will snap back into position and pinch the fuel tank with the weatherstrip in between, which I'm not happy about but I'm not seeing other alternatives. The 3/8'' clearance that I need is not trivial so I'm not sure trimming the tube is something I should consider. Also, so far I haven't made any chassis modifications.

Thoughts?

Subscribing to this post :-) I'm about to swap my racing Fuel Cell with the Breeze fuel tank. Curious on strategies..

I've never had trouble getting those down tubes to permanently move enough to fit comfortably. They're just thin wall tubing and in my experience bend relatively easily. I've also used a dead blow hammer. If you're not comfortable hitting them hard enough, maybe a really large adjustable wrench or clamping a 2x4 on them and bending. (Just brainstorming, haven't tried either.) Doesn't look like you've damaged anything other than the finish on the tank. But I wouldn't clamp the tank up there until that pressure is relieved. Don't cut anything. You also may want to flatten the flange just a bit more. You need the plastic bumpers on the end of those tubes sitting down onto the flange as far as possible to get the bolts in.

I had to use a strap to pull the forward one on the passenger side about a half inch forward and then once the tank was installed I released the tension on the strap.

I agree with EdwardB that the tubes should bend fairly easily, but I had trouble getting one to move (I think it was the passenger side which needed to move about 3/8” as well). I was worried able breaking the weld by applying too much force with the ratchet strap, so I braced the weld with a scrap piece of wood that was cut to length. I then pulled the tube with the ratchet strap. Sorry, I checked and I could find any photos.

I had similar issues. Tried a dead blow hammer, but the bar would just vibrate and not bend. Didn't try the straps. I ended up using a very large crescent wrench (about 2 feet), grasped it at the end and used brute force. The leverage was enough to bend the bar. I don't remember how far I tried to bend the bar as it would return to the original location, but it was significant. I had to push it hard enough that I was afraid I was going to pop the weld. But everything held and my tank is in.

Slide a cheater pipe over the tube and bend.

I had to bend mine as many others have. you just need to use a bit more force. As Edward said they are thin walled, tubing, they will yield with enough force.

Quote:

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Originally Posted by Railroad

Slide a cheater pipe over the tube and bend.

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That’s your answer! No need to make any more difficult than necessary.

Jeff

Well, I tried all these methods and while the tube would move with the force, it always returned to its original position. Eventually, I took out the plastic plug at the bottom of the 3x4'' tube, stuck a piece of rebar, and went to town. I protected the weld with a couple pieces of wood and a clamp. I'm not a scrawny guy and it took a lot more force than mentioned... Perhaps this piece got welded by someone at FFR who wanted to make sure it was all solid? :p

Attachment 175932

Anyway, as always, thank you! Onto the next problem :)