Thread: Gav's 101.

Yeah, fuel pickup will need to be almost 100mm longer. Drain plug I may have forgotton about.

I should have jumped in earlier, and asked for a second tank to be made up...

Imagine my fuel range then - 160ltrs + (100 in Jerrys)

Let me see if I can make one that holds fuel first...

Originally Posted by Homestar

Let me see if I can make one that holds fuel first...

If it`s anything like your cooking Gav Anything is possible

Spent about 4 hours on the new tank today. Got it more than half done, and it's coming together well. The tank was folder up in 2 bits, so the top needed to be welded on first to form the basic shape. I welded the top both inside and out so I can grind the weld flat on the outside so it looks like a bought one, the trimmed the baffles up to fit. Measured up where the sender and pump will go so I don't hit a snag later and welded in one baffle, the welded the end to it.

My welding isn't pretty but I was happy with the bead I was laying in and I'm confident it will be sealed. . Before I drill all the holes for the sender, pump, etc, I'll just have one hole in there as I finish off the welding so I can more easily pressure test it for leaks once this bit is done.

You can see the size difference between the old and the new here.


Inside showing one of the baffles.


Outside showing one end welded in and a bit of the front weld ground back.


One think I will say is that it's bloody heavy! But the long range tank I stuck into RRC was too and the mountings on that don't look as strong as what the 101 has, so I'm pretty sure it will be ok.

hi gav
you done great job on your fuel tanki made my bigger like you have done
130 ltr working on putting another on passanger side harry ho har in process of finishing off 160 ltr allietank
cheers cooee

Originally Posted by cooee

hi gav
you done great job on your fuel tanki made my bigger like you have done
130 ltr working on putting another on passanger side harry ho har in process of finishing off 160 ltr allietank
cheers cooee

Aluminium would have been better for this, but I have to work with what I can weld, and an AC TIG is one thing I don't have in my welding cupboard.

I'm pretty sure the outriggers will hold this one up easily, and as far as overall weight goes, the heaviest it ever gets is when there's our camping gear in the back.

Tanks on 101s lighten up quickly anyway!!!