101FC Fuel Tank Options

[stuee]

As the title suggests I am chasing up some options for replacing or properly repairing my rusted out fuel tank. I don't particularly like the existing design as its a terrible (or should that be good ) water trap, and any repairs I get done will most likely rust out again in the future. I imagine any repair would also take a bit of work, as the metal is quite thin in some places and there are 5 or 6 small holes ranging from 0.5-2mm in diameter.

I'm also not particularly fond of the 425 pounds + shipping for the clubs stainless steel option. Would be nice, but at this stage I'm not really wanting to outlay that much. Also I'm not sure if the baffling has improved on those tanks, but I gather its crap in the originals.

One option I've discussed with mates is simply mounting a slightly smaller new tank (either a modern plastic one from a wreckers or a fabricated tank) where the old one used to sit, and cut up the existing tank to simply cover the new tank so it looks original.

Has anyone else got any ideas? I've seen some have mounted additional tanks, while others have gone lpg.

[stuee]

Just adding some ideas as I find them. Rather than resolder the tank its been suggested in the below thread on the 101 forum to sikaflex it in place. This would remove the need for re-soldering the tank in place which would damage any paint, leading to early rust.

http://www.101club.org/forums/viewto...el+tank+cradle

Also is the fact that the metal is thin some spots on the tank going to be an issue? It is mounted in quite a solid cradle, and I will also be putting a membrane type coating on the inside as well. Possibly still prone to cracking but its well protected from stones and rocks gouging the tank.

[Lotz-A-Landies]

There are numerous brands of fuel tank sealants and most are aviation rated so cracking is not a great issue. On the other hand Sikkaflex can be a beast to work with and is best used on clean dry surfaces bonding two sheets together, so unless you are planning on dismantling the tank to re bond, or like the look of Sikkaflex rubbed over the seams I'd be going with the sealant on the inside.

You will have to take the tank out to seal it properly.

[stuee]

There are numerous brands of fuel tank sealants and most are aviation rated so cracking is not a great issue. On the other hand Sikkaflex can be a beast to work with and is best used on clean dry surfaces bonding two sheets together, so unless you are planning on dismantling the tank to re bond, or like the look of Sikkaflex rubbed over the seams I'd be going with the sealant on the inside.

You will have to take the tank out to seal it properly.

Sorry, should have worded that better. Currently the tank and carrier are removed and separated. If I were to repair the tank I would get the small holes braised up (by a shop - I dont have the equipment or experience for that) then get a KBS kit to seal the inside of the tank, and probably coat the outside of the tank a polyurethane type paint.

The sikaflex would be used to bond the tank back into the carrier as opposed to silver solder that the factory uses. I was previously concerned about soldering the tank back in as it would damage the paint and make it easy for rust to take hold but I had never thought of sikaflex (have to start thinking outside the box more...).

[Mick_Marsh]

You could get a custom tank fabricated in stainless here.
I've seen a few of the Aussie 101's with custom, larger capacity fuel tanks that appear to be fabricated and installed whilst in service.

[stuee]

You could get a custom tank fabricated in stainless here.
I've seen a few of the Aussie 101's with custom, larger capacity fuel tanks that appear to be fabricated and installed whilst in service.

Any idea of the $$$ involved. Although its a simple fuel tank, I cant see a custom job being cheap

I will ask about, I may be surprised.

[101RRS]

For the first 2 years of ownership of my 101 I thought my tank was standard but it is not - it has the correct inlet pipe and the correct fittings on top but was fabricated in Aust and is of much heavier construction than the original. Mine is fully welded with different mounting brackets.

See some pics below - if you do get one built I would consider making it a bit deeper - maybe up to another 2".

[stuee]

Thanks for the pics Garry. That looks like a nice solid tank.

Ringing around just then, a fuel tank repair would cost anywhere from $250 to $400 depending on how much work needs to be done, while a custom aluminium job would be about $800 for a tank of similar size, including a new sender and certification. They could do it in steel but said would not be that much cheaper. I'm still trying to find more companies that will custom make tanks to compare prices.

Either way it doesnt look like it will be cheap. I'm still waiting on hearing back from a friend of my brother who may be able to repair the tank for me.

edit* Just had another mob tell me that custom tanks start from about $2250!!!!

[Mick_Marsh]

Any idea of the $$$ involved. Although its a simple fuel tank, I cant see a custom job being cheap

I will ask about, I may be surprised.

It would have to be cheaper than getting the one from UK.

[101 Ron]

For the first 2 years of ownership of my 101 I thought my tank was standard but it is not - it has the correct inlet pipe and the correct fittings on top but was fabricated in Aust and is of much heavier construction than the original. Mine is fully welded with different mounting brackets.

See some pics below - if you do get one built I would consider making it a bit deeper - maybe up to another 2".

Could be a Aussie army modification as my fuel tank is like you describe of being much heavier constrution and professionally made of about the same size.
What is the differences in mounting to a standard tank Garry ?
as I have never looked carefully at a standard tank.


Stuee I would look at getting a steel tank made and as fuel tanks go it is a straight fordward one to fabricate.
As Garry has pointed out it would be a great time to made the tank deeper as the 101 needs to carry every drop of go juice it can