Frontrunner 45l Fuel Tank install (Part 2)

[Mudnut]

Once the washer, and "valve" were threaded over the wire, and dropped into the tank (Read very nervous about loosing it), I could see the tip at the bottom of the hole I drilled. Came up with a solution to line it up with the hole, so it could be fed through. Used a scrap piece of wire, and fed it into the end of the valve from the outside of the tank. Was able to line it up with the hole, and wiggle it through. Again what I thought was going to be difficult turned out to be simple.

http://www.aulro.com/afvb/attachment.php?attachmentid=32231&stc=1&d=1294461638

Showing the wire scrap, and valve protruding from the tank.

http://www.aulro.com/afvb/attachment.php?attachmentid=32232&stc=1&d=1294461725

Valve with wire still protruding, but washer, and nut tightened. I would wrap the whole valve stem with teflon tape, in the future. I still might do this if any drips present, as the threads are a potential source of leaks.

http://www.aulro.com/afvb/attachment.php?attachmentid=32233&stc=1&d=1294461913

The tank ready to install. The 100mm piece of pipe that is cut off from the existing filler pipe was the most difficult part of the install to accomplish. The new tank has a very sharp outlet port, and the space is very confined. Ended up loosely attaching it to the tank, and wedging it up, and on to the tank filler of the existing tank. A bit of lanolin helped with this. Took about an hour to do this one step (with much muttering, as my son was around)

http://www.aulro.com/afvb/attachment.php?attachmentid=32234&stc=1&d=1294462251

Tank finally in place. Top bits were easy to install. I used Tek screws to secure the bracket to the rear crossmember. Tightened them up, then was able to secure the front bolts. There was about a 20mm gap between the brackets, but tightening the bolts bent the bracket to securely hold the tank in place.

All the other lines were easily placed, and it holds fuel. Still need to attach the mud flap, but mine is rotting, and cracked in several places. Will get a new one, and fit that.

About 5 hours of work, and much satisfaction.

Cheers,

Ken

[grover7488]

good work Ken. What size tyres do you run? I've heard that 33's will rub the tank. What do you think?

BTW that is one FLASH garage floor:o

[Mudnut]

They are the standard General Grabbers that came with the Defender. I also have BF Goodrich MTR's in the same diameter. Have about 100mm clearance to the tank from them. By the way the garage floor is in the house we are renting. Have yet to move into, and build "MY" garage. :D

[grover7488]

thanks for the info
with a 100mm seems 33 should fit without any dramas :cool:
cheers

[stevencam]

Hi guys
Heres a couple of snaps of my frontrunner tank and 255/85 BFG certainly a tight fit

[Mudnut]

Hi guys
Heres a couple of snaps of my frontrunner tank and 255/85 BFG certainly a tight fit

Hey stevencam,

That sure is a tight fit.:o Would you have a bit more clearance if the back of the tank was lifted off the rear crossmember? It would be an easy check to do, by lifting it and putting a block between the crossmember, and mounting flange. A 25mm lift there would give a fair bit more clearance, as the front bracket is fairly high (the front brackets would have to be loosened also to allow for any pivoting). Also this should not affect the lines much. Just a thought.

Cheers,
Ken

[cols110]

I am just about to fit one to my TD5 110, I am also running 285/75s so will make sure I fit the tank as far rear wards as I can after seeing those photos.

I didn't really think about the clearance to much when I brought it. Are you on lifted suspension or std springs. I have a lift but might consider fitting another 1 inch spacer as well if needed to give it some more clearance.

[stevencam]

The tank is mounted as far back and as high as it can go, there may be room to go higher but you would have to redo all the mounts and reposition the filler. The rear springs are OME medium duty which give a lift of about 30 mm. The Defender was fully cross axled in those shots with the axle about 20 mm of the stops. It is a concern that the tank or other components may be stressed by contact with the wheel.

[cols110]

I got my tank fitted a couple of weeks ago, pig of a job doing the final fit and connecting all of the hoses.

I run the balance pipe through the sway bar bracket to help give it a bit more protection instead of just under the chassis rail.

With a lift and pushing the tank back as far as I could I still have good enough clearance from my 285/75 BFG A/Ts which was a relief, there is a chance it may just rub on full articulation when heavily loaded, but if this happens I will probably just fit some poly airs to the rear springs to ensure it stays that bit higher when loaded.

I am more than happy with the instillation now that I have a decent qty of fuel onboard without having to dive into the jerry cans each time I head into the desert.

[pope10001]

Thanks this is a really helpful post.

Mark

[applemac]

I got my tank fitted a couple of weeks ago, pig of a job doing the final fit and connecting all of the hoses.

I run the balance pipe through the sway bar bracket to help give it a bit more protection instead of just under the chassis rail.


I also found the balance pipe to be a very weak point (sticks, tall grass, etc. can easily cut it) and I put a temporary protection plate till I get a better one done (see photos).
This plate already saved my life as I was deeply bogged in mud (up to the chassis) when I was in the red center last April/May.

As far as clearance between the tire and the fuel tank, there is not a lot if the axle moves up. The tires are standard size.

I like the fact that the tank is gravity feed, but creates a problem that can get you stuck anywhere in the bush, all it takes is a stick and you loose all the fuel.

[Maverick_007]

Looks great.

Does anyone know if this style tank will fit into a arrange Rover Classic?

Cheers

[Robmacca]

Opening up an old post again....

These inner guard fuel tanks - I can't see from the photos whether there was an outlet bung install on the surface that faces the rear tyre?

I'm currently running 265/75/16 tyres and looking at installing a sill fuel tank - just wondering if anyone has successfully done this? If so, can u still run a larger tyre (255/85/16) still w/o it rubbing on the inner guard tank?

Also, the plan is to use the existing fuel filler to fill the Main / Inner Guard + Sill tanks - has anyone done this? Pics?

rob