How many of you have done a relocation to your gas cap on CJ/YJ's? Either b/c of a huge spare or just for shits and giggles? Im just interesed in what I need thanks

You are going to end up incurring a good amount of sheet metal work. This will not be a simple cutting of out your existing fuel filler neck and another hole to pop it into. You will need to relocate the entire fuel filler portion to another location that will still allow free flow when refueling. All of the other lines attached to the filler neck will also have to be rerouted to the new location with no leaks. The reason for this is that your tank is pressurized as part of the smog system(at least where I have lived). You will then have to tack it flush in the new location and finish the metal work, seal it, prime it, paint it. Bondo and/or filler putty will have to be used to get back the smooth finish of stock or its gonna look ghetto.
Wanna save yourself a crap load of work and keep your smooth body panels? Go with a swing away tire carrier. Most of these will also have a place to mount a 5 gallon gas can, and some have a license plate relocation kit with lighting to keep you legal. IMHO, this would be your best bet! Good Luck, Keith aka TIGGER4X

:rolleyes: :confused:

This is a common conversion here on the east coast. The pumps around here make it impossible to fill the YJ tank. I will be doing this conversion soon, but I am going the easy way. I am going to have Avalanche Engineering make me corners with the cut out already in them and then I will just cut the hole in the body after it is installed. If you want, get a TJ black plastic piece that bolts to the body and line it up on the fender. Put is high enough up incase you want to convert to TJ flairs one day. Mark the round hole and cut. The plastic piece will cover up any imperfection. Get a TJ filler neck from the dealer or junk yard. They are only $20 new. They all you have to do is either buy the TJ filler hoses or I have seen people cut the YJ hoses in half and use a piece of metal electrical conduit as a spacer and hose clamp the thing together. There may me some interfearence with some of the interior body panel when you cut the filler, but I am sure you can work through that. I will see if I can find you some pics.

BTW, this guy had a bunch of the black plastic pieces because he replaces them with chrome at his shop. I paid $10 for one.
Andreas 770-424-3323 just call and see if he has any left.


Here is a pick I found:

http://offyourrockers.com/Jeff_McRae1c.jpg

There is even a better explanation here:
http://forums.jeepsunlimited.com/ubb/Forum34/HTML/004400.html

My brother relocated his, similiar to the jeeps above but higher on the body. He did it because he had to after getting a custom gas tank made that sat higher up under the frame and inside the tub. Looks cool! He used the YJ filler and cap rather than the TJ one... Sorry no pics. My Filler is going to be attached to the roll-cage in the back after the fuel cell gets installed in the tub.. :D

I switched to a TJ filler. As noted above it was quite easy to do.

I'm using the old YJ gas filler (behind the licence plate) to run my OBA out of.

I relocated mine to the driver side fender well when I raised my tank 7". Theres really nothing too it. The hardest tyhing is finding filler hose, with the right diameter and the bends you need, But I had enough stuff lying around from other vehicles to make it work.

:eek:Shiat! Sorry for the long winded and not so relevent infor mation I first gave. I am too used to doing the full custom fab job on my FSJ Cherokee and not have access to all of the kewl upgrades readily found everywhere. This sounds so easy I would do it twice. :laughing:

Originally posted by DE Jeeper
:rolleyes: :confused:

(snip)

Here is a pick I found:

http://offyourrockers.com/Jeff_McRae1c.jpg

There is even a better explanation here:
http://forums.jeepsunlimited.com/ubb/Forum34/HTML/004400.html

Now where have I seen that YJ before? Oh yeah, parked in front of my house.

Had I known the "writeup" was going to get cross pollinated, I would have spent more time on it. :D

I was just sharing with those who don't get to surf the internet all day like me. BTW, nice mod.