Converting a Td5 long range tank to conventional pickup

[steveG]

I've got a long range main tank from a Td5 110 that I'd like to fit into my Isuzu County for a bit of extra capacity.

Being a Td5 tank, its got the big round mounting hole for the in-tank pump and fuel sender instead of just a pickup tube.
From what I can work out, I just need to fabricate some sort of plate with a pickup tube that will mount in the pump hole, and the sender will also have to mount on the plate.

Has anyone else tried this before?
Is it do-able, or am I just wasting my time and would be better trying to sell/swap the Td5 tank for a long range one from a Tdi.

Steve

[langy]

Have a look at the TD5 in tank fuel assembly. The last time I had a look at a Disco one, once you remove the in tank pump itself, the only thing one would need for use (from my point of view being a 300tdi owner) in a diesel application was an extension tube attached to the stub where the pump would have attached. After all, that's what the 300tdi fuel pickup is.

[Bundalene]

The Puma pick-up should fit, with no in tank pump. Adapting the lines at the top may be a bit more challenging but do-able and as for the fuel gauge, the resistance readings are in the pic ?


Pic of a Puma unit.


Uploaded with ImageShack.us



Else, do you have the TD5 pump mount ring (if not I have a spare you are welcome to) then fabricate your own from a bit of plate, using an original seal. This will enable mounting a standard aftermarket gauge as well.

Erich

[steveG]

Thanks Erich. I've got the pump mount ring so I think the idea of fabricating a plate and using an original seal is the way to go.

I just had a look on eBay and there is a Series III pickup and sender that looks like its pretty close to what I need and seems easy to adapt.
Fuel tank sender unit for Land Rover Series 3 LWB | eBay
Should be able to just mount that to the tank plate and then sort out pickup length and float range.

Steve

[steveG]

Finally getting back to this project.

Turned up a piece of 5mm flat and put a groove into it for an o-ring :



On the plate will be mounted a standard VDO level sender, and the fuel pickup.

I'm still deciding between a rigid or flexible pickup tube. A rigid tube always has the risk of getting squashed/bent if the tank takes a big hit in the wrong place. I'm thinking some 10mm nylon airbrake hose would make a good pickup and would just need a barbed fitting on the plate to connect it to.
Its semi-rigid, but would just bend a bit if the bottom of the tank was dented in.

Steve

[roverrescue]

Does the tank you are modifying have a sump or baffled area to pick up fuel from?

If not maybe incorporate that into your setup. My second 75L tank under the tray is flat bottomed and a pia when low on fuel on down hills the dieso runs away from the pickup and the old girl gets thirsty.

S

[steveG]

Does the tank you are modifying have a sump or baffled area to pick up fuel from?

If not maybe incorporate that into your setup. My second 75L tank under the tray is flat bottomed and a pia when low on fuel on down hills the dieso runs away from the pickup and the old girl gets thirsty.

S

Good point - no its pretty much flat in the pickup area. Has a full height baffle about 1/3 in from the LH side, but the rest is unbaffled.
In saying that though, the actual flat area is probably only about 40cm wide x 30cm, then it angles up towards the rear of the tank. I'll have a better look tonight and work out the minimum fuel level and angles that would be likely to cause a problem.

Steve