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  1. #376
    FEP Supporter BMW Rider's Avatar
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    Started on this winters project to replace the plastic fuel cell with an aluminum one. I have had issues with the top on the plastic one sagging down and with constant fuel odor in the trunk. I replaced the filler cap previously but suspect the issue is the sender unit as there appears to be some staining around the contact stud. Also due to the sag in the top, the sender does not sit properly and the gauge reads inaccurately. I also decided I wanted to drop the cell lower in the trunk to firstly lower the weight down in the rear, and secondly to allow at least a small amount of space in the trunk to toss in a bag or other items once in awhile.

    I welded up the frame over the past couple of days and once I get it cleaned up and painted it will be ready to do the swap. I made the frame in two pieces as I was unsure I could get it maneuvered into the trunk past the roll cage bars as a whole. The top support will span across the frame rails on top of the trunk floor, the bottom cage will then bolt up into place with the tank secured by the top bars. There will be rubber isolating tape applied to the frame to protect the tank as well.

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  2. #377
    FEP Supporter BMW Rider's Avatar
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    I attacked the car today, removed the old tank and got much of the fabrication work done on the opening to fit the new tank.

    The old plastic tank
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    Tank removed
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    Old pan removed
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    New sheet metal pieces fitted
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    Bottom view
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    Next task will be to weld it all up in the car and get some paint on it before installing the new tank.

  3. #378
    FEP Supporter BMW Rider's Avatar
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    Finished the installation of the new fuel cell in the car.

    Filler plates and the support frame welded in.
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    Ready to paint inside the trunk.
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    Painting done and tank in place Looks much tidier and more profesional.
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    Bottom view.
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    Just need to put fuel in it now and ensure all the connections are leak free. I'll probably also redo the rubber mats on either side to clean up the appearance of the floor a bit better. The ones I had before in there will not fit around the new framework properly. That's a minor detail.

  4. #379

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    Wow man that is a killer install for sure! You have great fabrication skills
    79 Zephyr, 4v/4r70w swap planned, with team z front and rear suspension, 8.8 and upgraded brakes and coil overs.

  5. #380
    FEP Supporter BMW Rider's Avatar
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    Got the final details cleared up today. Fuel in the tank and no leaks (not that I expected and, but always good when it turns out that way). Cut the new rubber mats to fit and laid them in.

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    Next thing I wanted to do was to make the shifter know smaller. I shortened it by 1.5" and reduced the diameter slightly as well. Better feel and makes the short throw shift lever actually shorter throw.

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  6. #381

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    You do incredible work, you should be super proud of that car man. Wow!
    One of the nicest foxes I have seen on the net.
    Makes my car look like a pile of puke but I’m ok with that lol
    79 Zephyr, 4v/4r70w swap planned, with team z front and rear suspension, 8.8 and upgraded brakes and coil overs.

  7. #382
    FEP Supporter BMW Rider's Avatar
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    Thanks for the praise. I do really enjoy the fabrication work and building things. Like most perfectionists, I am obsessed with the details and the things that don't seem just right which was why this fuel tank situation was nagging at me. I sometimes think that I get more enjoyment from the build than the ride, but then someone gives you a big thumbs up and it makes the ride a ton of fun.

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