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Thread: Developing HD plastic sill tanks for Defender

  1. #1
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    Developing HD plastic sill tanks for Defender

    G'day all, I'm in the early stages of design and development of heavy duty rota moulded plastic sill tanks for Defenders. I've been planning to do this for about six years and are finally doing it. The plan was to make one for my own defender first and then make them for all the common Tupperware vehicles to hopefully make some money, but ARB have buggered up that idea when they recently released there range of plastic long range tanks... But they don't and have no plans to make one for the defender so I'll give it a go. At least it was good conformation of all the reasons why plastic is better than steel for tanks including, heaps lighter, stronger, won't rust, bigger capacity because you can make better shape, etc. And depending on the type of plastic used can be for diesel or water.

    I'm just after some feedback, input, ideas from those who can help with things like;
    * shape/profile, who hits their sill tanks?
    * who has a steel sill tank, how much clearance is around the tank?
    * filler set up's, transfer pumps, gauges, switches etc

    For those that don't know rota moulded plastic tanks have no seams and are incredibly strong at resisting impact, however I will probably still offer a bash plate for those concerned about the possibility of a very sharp rock that may be able to cut into it. I'll do some testing.

    I'm making it for a 130 driver's side first, and expect it to be close to 100 litres. It's all along the sill, not up under the drivers seat so that storage compartment remains. I also plan to make the passenger side in diesel or water ( will hold a bit less due to battery box), and then make for 110 and 90 if there's enough interest.

    Tell me what you think!!

    Cheers, Andrew.
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  2. #2
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    Start with a 110 version, preferably passenger side and something that would work with water. I can do my own fittings, so really just the box with baffles and mounts and I will be a happy man.

    Haven't you got any idea of cost? I want to do a full tank replacement before fittings sills, but definitely interested in a water tank for the passenger side, which would probably dictate sill tank on drivers just to even things out!

    If you are Sydney based I am happy to lend a helping hand, keen to see how these things are done.

    Sent from my SM-G900I using AULRO mobile app

  3. #3
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    I had the Frontrunner sill tanks in my D90. Daniel at the expedition centre sell a split filler for Defenders that is plastic welded. The Frontrunner tanks come with their own fillers but Daniel's mod saves making more holes in the side of the car and worked a treat.
    [SIGPIC]

    2012 LR Defender 90 (BERT) Gone
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  4. #4
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    Quote Originally Posted by carlschmid2002 View Post
    I had the Frontrunner sill tanks in my D90. Daniel at the expedition centre sell a split filler for Defenders that is plastic welded. The Frontrunner tanks come with their own fillers but Daniel's mod saves making more holes in the side of the car and worked a treat.
    Thanks was thinking of Daniel's fillers, the split filler is the way to go for most people for sure.

  5. #5
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    Fillers and their location were the main thing that put me off steel sill tanks. Having to lift the seat to fill the tank was not an option. A well thought out split filler would work.
    I had a "discussion" with a servo operator at Port Augusta recently because I was filling a certified diesel transport tank on the back of my 130 where he shut off the bowser and refused to serve me, I can only imagine his reaction if I was filling an aftermarket tank under the seat.

    Provision for a fuel level sender would also be a nice touch that would not be difficult to incorporate when making the tank.

    Good luck

    Regards,
    Tote
    Go home, your igloo is on fire....
    2014 Chile Red L494 RRS Autobiography Supercharged
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  6. #6
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    Quote Originally Posted by JoeFriend View Post
    Start with a 110 version, preferably passenger side and something that would work with water. I can do my own fittings, so really just the box with baffles and mounts and I will be a happy man.

    Haven't you got any idea of cost? I want to do a full tank replacement before fittings sills, but definitely interested in a water tank for the passenger side, which would probably dictate sill tank on drivers just to even things out!

    If you are Sydney based I am happy to lend a helping hand, keen to see how these things are done.

    Sent from my SM-G900I using AULRO mobile app
    Hi and yes I can see that there would be a lot bigger need for 110 tanks and I will be doing them, but I have a 130 so it will be first

    And good idea about supply the tank only to people who wish to fit and plumb it all up themselves. But I also plan to have a complete kit and even drive in drive out fitting if needed.

    Cost will be no more than a steel tank, aiming to be a fair bit cheaper which is yet another advantage of rota moulded plastic.

    Why would you choose to replace the main tank first? You only gain about 30-40 liters more, hangs down low a fair bit, weight behind the axle, and costs about the same (or a fair bit more than my sill tank) as a steel sill tank, where you gain about 70-80 Liters for a 110. So for no more money you get twice the capacity gain, weight is centered, no low hanging tank at the back, fuel in two tanks for safety ie; won't loose all your fuel if you put a hole in one large tank.

    Not in Sydney, about 6 hours away in NE Vic, Beechworth, but welcome to call in if ever down this way.

    Cheers, Andrew.

  7. #7
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    Watching with interest...in each of diesel and water.

  8. #8
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    Quote Originally Posted by Shingleback View Post
    Hi and yes I can see that there would be a lot bigger need for 110 tanks and I will be doing them, but I have a 130 so it will be first

    And good idea about supply the tank only to people who wish to fit and plumb it all up themselves. But I also plan to have a complete kit and even drive in drive out fitting if needed.

    Cost will be no more than a steel tank, aiming to be a fair bit cheaper which is yet another advantage of rota moulded plastic.

    Why would you choose to replace the main tank first? You only gain about 30-40 liters more, hangs down low a fair bit, weight behind the axle, and costs about the same (or a fair bit more than my sill tank) as a steel sill tank, where you gain about 70-80 Liters for a 110. So for no more money you get twice the capacity gain, weight is centered, no low hanging tank at the back, fuel in two tanks for safety ie; won't loose all your fuel if you put a hole in one large tank.

    Not in Sydney, about 6 hours away in NE Vic, Beechworth, but welcome to call in if ever down this way.

    Cheers, Andrew.
    The replacement tank is 140L so a fair bit bigger than the standard one. It doesn't seem to hang too low, but I get your point on both fronts. I haven't decided either way yet.

    I figured yours would be done first, but when you want to do a 110 let me know - if it's towards the end of the year I may be down that way to ride so can do some fitting etc so you know what works and what doesn't for future reference and to know what is needed in packs to sell.

    Joe

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  9. #9
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    Can the plastic be used for drinking water? Ive always wanted a sill tank for water but wouldnt need to be so big, 80L would be fine.

    Beechworth is a great town, love the brewery there!
    1998 Defender 4bd1T

  10. #10
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    Here's a picture and dimensions which you may find useful, for a batch of steel tanks I had made for 110's quite a few years ago.

    A few pointers to watch:
    1. Not all Defenders enjoy the same dimensions. I had to reduce the width by 10mm after discovering that the initial batch wouldn't fit a friend's 110. Dimension shown on attached drawings is after correcting for width.
    2. Pay special attention to the breather line/s to avoid slow filling &/or possibility of airlocks and not achieving full capacity. I'd fit front and rear breathers if I ever made these again.

    These tanks don't wrap around chassis outriggers and have a capacity of 55 litres (drivers side) and 35 litres (passenger side). Also, tanks don't protrude below chassis rails.



    HTH
    Attached Files Attached Files
    Roger


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