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Thread: Frontrunner 45l Fuel Tank install (Part 2)

  1. #1
    Join Date
    Jan 1970
    Location
    Just North of Cairns
    Posts
    621

    Frontrunner 45l Fuel Tank install (Part 2)

    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...1&d=1294461638

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

    http://www.aulro.com/afvb/attachment...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...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...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
    Attached Images Attached Images
    Living the good life north of Cairns

  2. #2
    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

  3. #3
    Join Date
    Jan 1970
    Location
    Just North of Cairns
    Posts
    621
    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.
    Living the good life north of Cairns

  4. #4
    thanks for the info
    with a 100mm seems 33 should fit without any dramas
    cheers

  5. #5
    Join Date
    Nov 2008
    Location
    Yarrawonga Vic
    Posts
    40
    Hi guys
    Heres a couple of snaps of my frontrunner tank and 255/85 BFG certainly a tight fit
    Attached Images Attached Images

  6. #6
    Join Date
    Jan 1970
    Location
    Just North of Cairns
    Posts
    621
    Quote Originally Posted by stevencam View Post
    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. 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
    Living the good life north of Cairns

  7. #7
    Join Date
    Jan 1970
    Location
    Dubai
    Posts
    535
    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.

  8. #8
    Join Date
    Nov 2008
    Location
    Yarrawonga Vic
    Posts
    40
    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.

  9. #9
    Join Date
    Jan 1970
    Location
    Dubai
    Posts
    535
    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.

  10. #10
    Join Date
    Sep 2011
    Location
    Dubai
    Posts
    1
    Thanks this is a really helpful post.

    Mark

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