TOTM: Unibody gas tank relocation [Archive]

Xjcrawler736

10-17-2008, 10:22 AM

Since the other thread got all messed up I will post up what i did. Pictures will come later since I am out of town.

I pulled the stock skid plate off dropped the tank.(took all hoses and connections off)

Took measurements of the tank and cut a hole in the floor that was the exact size of the tank, minus the welded seem all the way around the tank.

I dropped the tank into the hole and had the seem hold the tank up. I also drilled a 1.5" hole for the sending unit wires and the feed and return hoses. Must be about 1.5" or bigger because the sending unit connector will not fit through it. And be sure to use a rubber grommet for the hole so you dont rip up any wires or lines. (spark+gas= :nuke: ).

Next step for me is to put a layer of 1" wide 1/4" thick rubber tape on the floor where the gas tank seem sits. (tape is from sealing truck bed covers) This will help with viberations. I am also going to make tank straps for the top and use the same tape between the straps and the tank.

I still need to mod the gas tank skid because it is about 8" tall now and I need it to be around 2". I am going to bolt it right in the original position after cutting it down.

Also when it comes to the fuel lines. I am thinking about running hard lines from the tank to the filter so I dont have to worry about any kinks with some of the hard bends it has now. (Also looks much cleaner) Steel braided are another option also.

I will be back at the shop next weekend inbetween business trips so I will get pictures and finish the project.

Andy

vetteboy79

10-17-2008, 11:02 AM

I did the super-scientific "put it in the cab" relocation.

http://photos-e.ak.facebook.com/photos-ak-sf2p/v82/53/103/24800499/n24800499_31184916_9013.jpg

Plop it on the back deck, add some straps, re-route the lines and wiring, go wheeling.

It's admittedly a hokey way to do it. I went this route for a few reasons:
- I was busting my ass to get out wheeling
- I didn't know whether I was going to do a fuel cell or propane
- I didn't know how much axle/exhaust clearance I needed underneath

So after a year+ of build time, I threw it in there so I could make it on a shakedown run. As with most things like that, it was done with the best of intentions to replace it ASAP with a permanent solution. That was April 2007.

A year and a half, dozens of wheeling trips, thousands of miles, three flops, and an exo-cage build later...it's still there. Works perfectly, doesn't leak, doesn't smell. I think I offically admitted defeat when I welded a tab on the exo bar to mount the filler neck to. I'll change it out someday...

BRIANHO13

10-17-2008, 01:00 PM

I did the super-scientific "put it in the cab" relocation.

Plop it on the back deck, add some straps, re-route the lines and wiring, go wheeling.

It's admittedly a hokey way to do it. I went this route for a few reasons:
- I was busting my ass to get out wheeling
- I didn't know whether I was going to do a fuel cell or propane
- I didn't know how much axle/exhaust clearance I needed underneath

So after a year+ of build time, I threw it in there so I could make it on a shakedown run. As with most things like that, it was done with the best of intentions to replace it ASAP with a permanent solution. That was April 2007.

A year and a half, dozens of wheeling trips, thousands of miles, three flops, and an exo-cage build later...it's still there. Works perfectly, doesn't leak, doesn't smell. I think I offically admitted defeat when I welded a tab on the exo bar to mount the filler neck to. I'll change it out someday...

This is pretty much what I did with mine, I would have sunk it into the floor but the plastic tank doesn't have a lip on it to accomodate this (its a 98).

supernatural

10-17-2008, 02:39 PM

What other solutions are there for the plastic tank crowd? :emb4:

I haven't pulled my tank yet since i'd like to come up with a good plan for the plastic tank.

Once i do figure out how i'm mounting the plastic tank, i'll be building an enclosure that will be a locking storage compartment, as well as making another flat location to throw my camping gear. I hate trying to pack when you have an odd shaped storage space to start with.

Maybe i'll make a cradle from the bottom, and strap the tank down on the top. The cradle will be incorporated into my storage enclosure. I'm thinking of using a piano hinge and a simple filing cabinet type lock for the storage boxes. Any ideas for different locking systems?

What do i need to watch for as far as using the stock gas filler location? I'd like to keep the stock location (for now).

I think having a power inverter built into the enclosure would be super sweet as well. You know, having that built up "table" for making dinner at camp, and having margaritas all in one spot! :blender:

JeepnTX

10-17-2008, 04:22 PM

wvredxj

10-17-2008, 05:13 PM

What are you guys with no chop doing for the main vent? Wonder how bad the fumes would be when filling if it was left inside?
heres my junk:

http://img.photobucket.com/albums/v513/bigwhitehd/98%20jeep/DSC01669.jpg

the gaps are less than 1/4" on the sides, the tank is not perfectly square (meaning the plastic isn't straight) so i will seal the gap with bead sealer.

http://img.photobucket.com/albums/v513/bigwhitehd/98%20jeep/DSC01670.jpg

the square tube is 1"x1"x3/16 on the front and back to give the floor some strength

http://img.photobucket.com/albums/v513/bigwhitehd/98%20jeep/DSC01671.jpg

xjtony

10-17-2008, 11:37 PM

Anyone done it with the cargo area still enclosed? If so, where was the filler hose relocated to?

I've got an 18 gal stainless tank that fits perfect in the cargo area, but with no chop-top, I'm kinda curious as to how to go about the filler neck.

Well i'm doing mine with all my interior still there... I just threw the tank and plastic skid in the back, using the plastic skid to isolate the tank from the body, got to make something to hold the tank in place tho. And the filler is just kinda laying there, vent line is ran thru the floor.... work still in progress

supernatural

10-18-2008, 10:36 AM

What are you guys with no chop doing for the main vent? Wonder how bad the fumes would be when filling if it was left inside?
heres my junk:

I'm hoping that the stock location will work for the filler hose and vent tube, but i'm waiting to hear back before i start cutting into my floor.

ashmanjeepXJ

10-18-2008, 05:16 PM

The rear window could be replaced with plexi and the fill neck mounted to the plexi window. Just below the window is still kinda low for where the hoses line up. Mine was always open, not enclosed.

I just cut the floor and set the tank in it. I was worried about a rear end collision. If I were to do it again I would have made a 3/4in box tube frame and weld that to the sheet metal so it would not slice open the tank in a rear end collision.

http://www.wheelingarizona.com/forums/files/P0001806_crop.JPG

http://www.wheelingarizona.com/forums/files/dave2_502.jpg

This is the king of Cherokee raised gas tank pics...
Air rams fully extended 16in (not ride height.:D:flipoff2::shaking:
http://www.wheelingarizona.com/forums/files/cherokeefullheight1.jpg

BigRedMachine

10-18-2008, 10:18 PM

I cut a hole in the floor and welded a peice of angle on the front side of the hole,then took the factory metal skid plate and cut the sides off and welded it into the angle and a bumper that I welded in. then set the tank into the skid and straped it down with a metal strapping. I welded chain links on every corner to run the strapping through.
http://i343.photobucket.com/albums/o478/wilson89xj/1017081522.jpg
http://i343.photobucket.com/albums/o478/wilson89xj/builpics.jpg
http://i343.photobucket.com/albums/o478/wilson89xj/1017081522a.jpg

blackglass

10-19-2008, 10:11 PM

Here is how mine was done on my 87.
http://img.photobucket.com/albums/v354/67temp/xj%20beater/build/DCP_3875.jpg

I place the stock skid in the hole. That skid really is too big to fit between the frame. It hit the frame mostly where it turns in above the axle. My 98's skid seemed to be smaller and would be a better fit.

http://img.photobucket.com/albums/v354/67temp/xj%20beater/build/DCP_3878.jpg

I ran a 2" square tube across the wheel wells for the front of the enclosure and also for future shock mounts. The top is hinged should I need access to the tank or pump. In this pic you can see where I was testing for the tire mount on top. Jack and spare shaft storage are on the sides. Then the enclosure got skinned.

http://img.photobucket.com/albums/v354/67temp/xj%20beater/build/DCP_3932.jpg

The distance from the tank to the diff with about 4" of lift.

http://img.photobucket.com/albums/v354/67temp/xj%20beater/build/DCP_3879.jpg

I did reuse the stock filler location but that isn't the best idea. Even with shortening the fill tubes the angle isn't great enough for proper flow into the tank. While filling I have to hold the pump handle so it flows at a slower rate.

artyart

10-24-2008, 06:02 AM

little jeeps can have a raised tank too, even though it started out for different reasons - a little backround, my fuel pump stb a while back, in the process of dropping the tank, I discovered that the pinholes were getting a bit big, and that rust was pretty well taking out the back end of the xj... out comes the saw ....

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank1.jpg

the rear quarter where the tank fill was was paper thin.... I poked it with my finger and it went thru, so.....

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank2.jpg

Moving on I found that the floor above the tank was pretty well rusted too....

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank3.jpg

Here's a test fit of the new tank..........

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank5.jpg

I ended up having to cut flush with the frame to get it to fit, (hadnt dawned on me how much work THAT was gonna end up to be.... you can see the skid I hacked up for underneath, it sits flush with the uniframe rails and bolts to the nutstrip for the hitch

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank7.jpg

I wanted this thing to be enclosed , this needs to pass inspection and at least look safe on the street..... so I framed out a cover with some 1/2" square tube, and skinned it with 16 ga sheet.

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank10.jpg

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank12.jpg

The finished setup looks a little like this........

http://i3.photobucket.com/albums/y93/artyart/Mods/liftgastank/tank14.jpg

No photos, there was some juggling to route the fuel lines , and power/sender lines, and I also raised up the fill about 6" and used a filler neck opening from a cj.

probably the most ambitious thing I have tried yet with this thing, (with my meager fabbing skills), but the jeep hasnt folded up like a taco yet, even with the boogers I have holding it together. One of the goals was to just use what I had on hand as far as steel, with all the crap I have lying around the house steel-wise, I think I put 2-300 bux into this , mostly for the cost of the fuel pump, tank, and some other small parts. Somewhere along the line I will most likely take some of it apart to raise shock mounts and do some other mods, but hopefully the little bit I planned ahead wont make that too painful.

When the heep is loaded up the top serves as a rack for stuff, and it looks almost normal if you just glance at it......

Weasel

10-24-2008, 01:12 PM

so what is the reason for moving it up, just ground clearance? I would think it would raise your CG quite a bit. Anyone notice this?

artyart

10-24-2008, 04:50 PM

It was a mod I was interested in, when the combination of a rusted out floor, and need for a new fuel tank and pump came around, I decided I would have
to give it a try. And yes it does bring up the cg , especially with the spare resting on top of it, but it doesnt raise it any more than putting the spare up on a tire carrier, or on the roof. (plenty of rigs around that have the spare way up high, that seem to do ok.)

xjtony

11-17-2008, 08:12 PM

pipehitter155

11-18-2008, 04:39 AM

reviving a thread... but im putting a RCI fuel cell in the back of my XJ and am wondering if i run the vent and roll over valve line through the floor if that will keep the fumes from being inside the cab? Only asking cuz i got my full interior doors and what not. Gets cold in the winter when we ride so i like to be able to roll the window up and turn the heat on!

yeah i don't see why it wouldn't...try it and report back....also post up some pics and what stuff you used for your fuel cell...i was going to do the fuel cell awhile back but ran out of funds..

hammerdownxj

11-18-2008, 09:47 PM

http://i471.photobucket.com/albums/rr75/hammerdownxj/IMG_1694.jpg

http://i471.photobucket.com/albums/rr75/hammerdownxj/IMG_1692.jpg

coppermtn

11-19-2008, 02:42 PM

gotta put mine in an astro, why mount it thru the floor, and not on top of the floor somewhere in the middle?

Evergreen12

11-19-2008, 03:21 PM

When I had my XJ I ran a 22 gal JAZ fuel cell that I recessed into the floor. I had our sheetmetal shop bend up a sump that was about 1/8" bigger all around and then I cut out the floor, dropped it in and spot welded it all the way around (I drilled 1/4" holes in the flange). I fabbed up straps to hold it in place.

http://inlinethumb04.webshots.com/835/2959543470049057516S425x425Q85.jpg (http://good-times.webshots.com/photo/2959543470049057516agrRoz)

http://inlinethumb23.webshots.com/27478/2934614460049057516S425x425Q85.jpg (http://good-times.webshots.com/photo/2934614460049057516caMkuB)

http://inlinethumb35.webshots.com/29410/2345300960049057516S425x425Q85.jpg (http://good-times.webshots.com/photo/2345300960049057516dNJKld)

This gained me at least 7" of ground clearance. I was always denting the piss out of the stock tank.

Xjcrawler736

11-20-2008, 07:37 AM

Evergreen12

11-20-2008, 08:16 AM

I had planned to build a skid under the cell but I sold it before I got around to it.

Chili Palmer

06-09-2009, 12:31 PM

Bumping for any more ideas...

I'll be doing this to my XJ this week/weekend and could use any info I can get...:flipoff2:

xo_jeep

06-10-2009, 11:07 AM

Bumping for any more ideas...

I'll be doing this to my XJ this week/weekend and could use any info I can get...:flipoff2:

Just the standard stuff. Some before and afters:

http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/IMGA0030-1.jpg

http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/IMGA0036.jpg

http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/IMGA0032.jpg

http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/IMGA0019.jpg

http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/IMGA0041.jpg

Most recent:
http://i271.photobucket.com/albums/jj137/chiko1269/LinkThread/100_2525.jpg

I am going to put a peice of sheet or plywood or something on the frame I built so I have more storage area.

Pre4runner

06-10-2009, 08:50 PM

Lifted mine about the same as the rest of these, half way, straps top and bottom.

Moved gas filler up like so
http://i175.photobucket.com/albums/w136/Pre4runner/XJ/Rear%20fenders/Wheelwellr.jpg
http://i175.photobucket.com/albums/w136/Pre4runner/XJ/Poser%20shots/20090416_0173.jpg

mud_slinga

06-10-2009, 10:09 PM

http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2801.jpg
http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2804.jpg
not so bad...
http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2806.jpg
http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2814.jpg
I just used the stock straps in the factory location for the rear of the tank. The front side I took and ran some angle iron and welded some bolts to it for the factory straps to bolt down to.
http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2831.jpg
http://img.photobucket.com/albums/v314/rock_crawler/Grand%20cherokee/Sinking%20the%20gas%20tank/103_2833.jpg
I still need to enclose the topside with some sheetmetal. the factory filler still works and the factory lines and all were long enough but just barely.

Chili Palmer

06-11-2009, 09:11 PM

I started on mine tonight. I got the floor cut and tank sitting there. Now I need to get some 1" square stock and make a frame and also figure out the straps...

Initial cut in floor...
http://www.nebrigich.com/gallery/d/4973-2/100_1919.JPG

Tank just sitting there for now...
http://www.nebrigich.com/gallery/d/4976-2/100_1920.JPG

From below...
http://www.nebrigich.com/gallery/d/4979-2/100_1921.JPG

From behind - which is how she likes it...:flipoff2:
http://www.nebrigich.com/gallery/d/4982-2/100_1922.JPG

91YEEPER

06-11-2009, 09:20 PM

recessing the 15 gal cell in the floor and taking this time to plate the rear frame section and reinforce the area that i plan on adding my lower link mounts to (when it gets linked in the rear).
cutting the hole.
[br]http://www.jeepaholics.com/support/files/91YEEPER/20081117111755_tank hole1.JPG[br]
made a steel basket to hold the tank, i have since plated it with 1/4" and put in a divider to keep the tank to the left.

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081117111936_tankframe.JPG[br]

i made a special carrier for clevis's, shackles, and a holder for my extra recovery shit.

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081117112052_tankhole2.JPG[br]

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081229222057_rack1.JPG[br]

i ordered some 3/8" heims for the rack to pivot on and 2 of those tension latches to hold it down. it will pivot back so i can fill it up without unloading aton of shit. i was gonna make the rack lower to the tank but i have a rectangle catch can/overflow bottle that the tank vents into and acts as a rollover valve. i also bought 2 strongarms (little hydraulics on trunk lids) assist in lifting the rack when its loaded and hold it up.

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081229222410_rack2.JPG[br]

i was able to get one of the guys in my welding clasd to finish building my tank skid and holder. its 1/4" ( i know alot but it was free) and i used rubber seam sealer to seal the tank to the front of the skid where the hoses go through so its still water tight.

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081229222606_tankskid.JPG[br]

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081229223315_rack3.JPG[br]

91YEEPER

06-11-2009, 09:26 PM

forgot to add, i gained about 6.25" of clearance from the s tock height.

Starboard M

05-08-2010, 02:18 PM

WA-HCRC

05-09-2010, 01:22 AM

Seems like most people are using the lip of the tank to support the tank and not running straps under like the factory setup. Has anyone noticed problems with this?

Is the lip and two straps over the top strong enough to keep the tank in place during a roll? Or is something more substantial needed?

Id also be curious as to how people relocated their filler neck or if they just left it in the stock location.

I used a factory skidplate with the flanges cut off, and welded into my floor that supports the tank 100% on the bottom. gonna strap it over the top similar to factory, but upside down sorta :homer: Its in my build thread, not in here.

Havent done my filler yet, no help there.

AgitatedPancake

07-29-2010, 12:11 AM

http://www.agitatedpancake.com/random/jeep/gastank/dscn3321.jpg

http://www.agitatedpancake.com/random/jeep/gastank/DSCN3338.jpg

http://www.agitatedpancake.com/random/jeep/gastank/dscn3344.jpg

http://www.agitatedpancake.com/random/jeep/gastank/DSCN3360.jpg

http://www.agitatedpancake.com/random/jeep/gastank/DSCN3366.jpg

http://www.agitatedpancake.com/random/jeep/gastank/dscn3394.jpg

http://www.agitatedpancake.com/random/jeep/fueltunnel/dscn3422.jpg

http://www.agitatedpancake.com/random/jeep/fueltunnel/dscn3431.jpg

http://www.agitatedpancake.com/random/jeep/fueltunnel/dscn3434.jpg

http://www.agitatedpancake.com/random/jeep/gastank/DSCN3342.jpg

AgitatedPancake

07-29-2010, 04:40 PM

Hmmm deja vu :D. Thanks whoever it was that decided to put a duplicate in here, I had forgotten about this thread

Chili Palmer

07-30-2010, 03:28 AM

Anyone rotate the gas tank 180 degrees so the filler neck is on the other side?

whitneyj

07-30-2010, 04:58 AM

Anyone rotate the gas tank 180 degrees so the filler neck is on the other side?

Yes.

The rear of the tank slopes back so I flipped it around when I raised it 9" to accomidate as much rear stretch as possible.

Just cut a hole through the rear 1/4 panel and mounted the filler tube to the outside.

ashmanjeepXJ

07-30-2010, 09:23 AM

Hmmm deja vu :D. Thanks whoever it was that decided to put a duplicate in here, I had forgotten about this thread

It just happens on its own... The gravity of tech... :flipoff2:

Chili Palmer

07-30-2010, 01:09 PM

Yes.

The rear of the tank slopes back so I flipped it around when I raised it 9" to accomidate as much rear stretch as possible.

Just cut a hole through the rear 1/4 panel and mounted the filler tube to the outside.

Cool, thanks.

Anything I need to look out for?

Action Fab

09-17-2010, 10:25 PM

Any one having any problems with fumes leaking into the cabin? I am starting my new ZJ build tomorrow, and one thing I will be doing is building a fuel cell to sit in the back where the spare tire goes. But I am affraid that I may get fumes in the cab. It will be full bodied and be completely sealed with windows up and hatch on. It may sit like that for weeks at a time. I dont want it to reak every time I get in it.

I have done a lot of tank relocations, just never put one into a sealed cabin.

xj9140

09-18-2010, 01:49 AM

I did mine a few months back. I do alot of driving with the windows rolled up and the AC cranked. I havn't noticed any fumes at all.

http://i149.photobucket.com/albums/s74/4x4hiker/Picture015.jpg

I welded in some angle iron around the hole and built a frame to clamp it down.
http://i149.photobucket.com/albums/s74/4x4hiker/Picture022.jpg

http://i149.photobucket.com/albums/s74/4x4hiker/Picture053.jpg

The filters mounted in front of the tank, behind a sheet metal guard

http://i149.photobucket.com/albums/s74/4x4hiker/Picture023.jpg

Somebody suggested drilling a hole for the fuel lines. I ran the lines through a factory drain hole. I still need to get a grommet

http://i149.photobucket.com/albums/s74/4x4hiker/Picture002-5.jpg

http://i149.photobucket.com/albums/s74/4x4hiker/Picture005-2.jpg

I didnt have a welding blanket, but I would highly recommend one for this project

http://i149.photobucket.com/albums/s74/4x4hiker/Picture004-4.jpg

I through down some plywood so I can haul stuff

http://i149.photobucket.com/albums/s74/4x4hiker/Picture191.jpg

To re-fuel I just open the hatch

ratmonkey

09-18-2010, 03:28 AM

Twisty

09-18-2010, 07:25 AM

Has anyone ever shortened the gas tank? i.e. cut it in half, take 6" out, and weld it back together? I've never looked inside the tank but I'd like a smaller one. Since I do not have enough money for a fuel cell now, and I'd like to keep the wiring stock, if it is possible I think I may try it.

Action Fab

09-18-2010, 07:52 AM

in most locations with an inspection (if you plan to keep tags and all on your rig) fuel must be kept separate from the passenger compartment.
i would personally make the bottom a permanent skid plate and have a gasketed bolt down top cover for the tank.

even so, your evap system and the check valve should take care of fume issues. you didn't delete the evap system yet did you?

I am in Arkansas, I could put a boat tank back there and be legal.

The evap will be gone since this is a ZJ and I dont have room to keep it.

Has anyone ever shortened the gas tank? i.e. cut it in half, take 6" out, and weld it back together? I've never looked inside the tank but I'd like a smaller one. Since I do not have enough money for a fuel cell now, and I'd like to keep the wiring stock, if it is possible I think I may try it.

I think that the XJ's tanks are aluminized, so welding may be a chore.

ashmanjeepXJ

09-18-2010, 09:26 AM

i was able to get one of the guys in my welding clasd to finish building my tank skid and holder. its 1/4" ( i know alot but it was free) and i used rubber seam sealer to seal the tank to the front of the skid where the hoses go through so its still water tight.

[br]http://www.jeepaholics.com/support/files/91YEEPER/20081229222606_tankskid.JPG[br]

Did you modify your pickup line so when you point up hill it will still get fuel?
That kind of tank I would have ran the pickup at the back.

91YEEPER

11-22-2010, 06:44 PM

Did you modify your pickup line so when you point up hill it will still get fuel?
That kind of tank I would have ran the pickup at the back.

some how i never saw this post..

i ran 18" of line in the tank with a semi stock style pick up and box in the actual tank. never had an issue out of it, but i didt try driving it on its lid or side either.

newman98XJ

11-22-2010, 07:49 PM

The rear window could be replaced with plexi and the fill neck mounted to the plexi window. Just below the window is still kinda low for where the hoses line up.

My work in progress
http://i30.photobucket.com/albums/c305/lax1785/XJ%20tail%20end%20rebuild/100_0589.jpg
It took some reworking but I got the stock recessed piece to work
http://i30.photobucket.com/albums/c305/lax1785/XJ%20tail%20end%20rebuild/100_0595.jpg

xj9140

11-22-2010, 07:59 PM

My work in progress
It took some reworking but I got the stock recessed piece to work

Do you think you will be able to take your hand off the nozzle when refueling. It looks like the nozzle would just fall out if you did. I suppose you could try parking on a block of wood or the curb and it would might stay in the hole.:laughing:Nice comp cut

newman98XJ

11-22-2010, 08:03 PM

Haha I actually though about that, it has about 20* of angle I dont mind standing there as long as the gas goes in the right direction.

JKMotorsports

11-22-2010, 08:20 PM

I'm digging for pics, but I cut a hole the size minus the weld seam, dropped it down, then built a complete cover for it. In the lid I made a round cutout and on the tank I epoxied a tight 90deg elbow and welded the factory cap thread to the elbow so that a factory cap will work through the hole. So to fill I just popped the hatch and filled it up.
BUt I'm BBQ juice now on the SBC.

Edit best I can find:
http://i66.photobucket.com/albums/h251/JK_Motorsports/Jeep%20Build/DSC_0014.jpg
http://i66.photobucket.com/albums/h251/JK_Motorsports/TankTuck.jpg
http://i66.photobucket.com/albums/h251/JK_Motorsports/TanFrame.jpg

Georgia boy '88

11-23-2010, 01:46 AM

My work in progress
http://i30.photobucket.com/albums/c305/lax1785/XJ%20tail%20end%20rebuild/100_0589.jpg
It took some reworking but I got the stock recessed piece to work
http://i30.photobucket.com/albums/c305/lax1785/XJ%20tail%20end%20rebuild/100_0595.jpg

Thanks for the last resort idea.:laughing:

I'm mid relocation and thinking something like this may give a little cleaner look.
http://www.4wheelparts.com/Exterior-Parts-and-Accessories/Fuel-Filler-Housing-by-Smittybilt.aspx?t_c=3&t_s=470&t_pt=3969&t_pl=101054&t_pn=S%2fB7508

I'm hitting the junkyard tomorrow to see if I can find something similar that will work for me.

xj9140

11-23-2010, 04:00 PM

Thanks for the last resort idea.:laughing:

I'm mid relocation and thinking something like this may give a little cleaner look.
http://www.4wheelparts.com/Exterior-Parts-and-Accessories/Fuel-Filler-Housing-by-Smittybilt.aspx?t_c=3&t_s=470&t_pt=3969&t_pl=101054&t_pn=S%2fB7508

I'm hitting the junkyard tomorrow to see if I can find something similar that will work for me.

Hell, for ten bucks why even bother going to the bone yard. Thanks for the link. I might have to give that a try.

CTeunuch

11-23-2010, 04:07 PM

I'm hitting the junkyard tomorrow to see if I can find something similar that will work for me.

Look for a TJ bezel, those work well on ZJ's, and we got one to work on my friend's XJ with only a little cutting.

I did the standard tank raise in my XJ, with the floor cut out and it resting on the lip, and now I'm having some issues. I can't fill it past ~3/4 of a tank, and for some reason it won't shut the pump off when it's full. I've been to multiple gas stations, so I know it wasn't a faulty pump, and at every one it kept pumping even when fuel was pouring from the filler neck. Any advice?

Georgia boy '88

11-23-2010, 04:20 PM

Hell, for ten bucks why even bother going to the bone yard. Thanks for the link. I might have to give that a try.

Because I'm an even cheaper bastard. Useful info I found at the bone yard today. The inset for a YJ is an almost perfect fit for the flat spot on an xj rear quarter, if turned sideways. The YJ filler neck is also much shorter and can likely be made to work with the stock hoses with a little ghetto rigging. :D

Hopefully I'll have some finished pics in the next few days, just need some good weather and free time.

Georgia boy '88

11-28-2010, 06:21 PM

Alright pics of my set up, The straps are temporary until I can get to the steel yard, and my padding under the tank still needs final trimming. So far no fumes in the cab either. The wires I extended, using heat shrink butt connectors then wrapped in electrical tape. In retrospect I wish I had run the harness side back through the body plug and kept all of the electrical inside the cab.

huntingman2706217

12-26-2010, 12:26 PM

anyone else got some pics of this with the metal tanks? my 95 i just picked up i bought with a bad fuel pump... went to pull it and the sending unit is rusted all to shit... so i gotta pull the tank from my 89 and i was thinking of going ahead and doing this since the tanks gonna be out and i gotta do all this anyways...

ezman

12-29-2010, 01:48 PM

i'll be raising my tank through the floor in the next few weeks... as soon as i get some more sheet metal to finish the inner fenders... so far my plan is to us the stock mounting location, but cut a wedge out of metal housing that the filler neck bolts to and bend it up slightly, then shorten the stock hoses... that way there shouldn't be any problems filling the tank. i'll post pics up as soon as i get it done.

xj_man_646

12-29-2010, 04:23 PM

I cut 2 pieces of pipe in half and welded them to the floor. Cut a square hole and routed the factory lines through it. Strapped the tank down with 2 ratchet straps and zip tied the filler neck in an upward-ish position. I still need to hold it up when filling but its no big deal. Hasn't been a problem yet and I can remove the tank in 5 minutes when needed.

CTeunuch

12-29-2010, 05:06 PM

Georgia boy '88

12-29-2010, 06:24 PM

Is that the YJ neck you used? What hoses did you use, YJ or XJ? How is it to fill?

I ended up using the XJ filler neck with the YJ bezel and the stock hoses trimmed a bit. It depends on the gas pump I use, but most of the time it fills just like stock.

calvin4186

12-30-2010, 11:09 AM

CTeunuch

12-30-2010, 04:11 PM

What are the dimensions of this hole cut for the tank relocation? and How far off of the back latch does it start?

I'm thinking of doing this, and wondering how much room I'll still have for a back seat in my 2 door.

If I remember correctly the hole is roughly 19"x32", but you should measure the tank to be sure. I based the cut off of the crossmember the shocks mount to, and I had enough clearance around the latch. The first time I did it, in a friend's XJ, we based it off the latch and ended up having to cut quite a bit out of the shock crossmember. There's still plenty of room for a back seat in a 2 door, the seats mount just like a 4 door. Here's a picture before and after for reference.
http://img.photobucket.com/albums/v89/frigidrebellion/2door/IMG_1708.jpg

http://img.photobucket.com/albums/v89/frigidrebellion/2door/IMG_1718.jpg

http://img.photobucket.com/albums/v89/frigidrebellion/2door/IMG_1896.jpg

ezman

01-09-2011, 06:53 PM

i'm not done yet, but here are a few pics...

this won't work, because you can't bend it in far enough to get a good angle

http://i1130.photobucket.com/albums/m524/cantkillit/fillerneckmockup.jpg

so i did this...

http://i1130.photobucket.com/albums/m524/cantkillit/fillerneckcut.jpg

i just have to cut a bunch of tiny little pieces to box it back in, then i'll be able to use the stock fuel door and filler neck...

ezman

01-10-2011, 08:20 PM

fortCollinsZJ

01-18-2011, 10:23 PM

here is the filler neck all welded up, it's almost a straight line down to the tank. sitting a about a 15* angle, just need to get some straight hose.

http://i1130.photobucket.com/albums/m524/cantkillit/filleneckfinal.jpg

I did something very similar on my jeep, now the gas sloshes out when I'm really off camber, or when I take hard turns on pavement with a full tank. Its not good.

Would it be a bad idea to put something like a globe valve inline to keep fuel from back flowing. Obviously there will need to be an alternate vent for the tank to relieve pressure, but how important is it for the vent to be the actual fuel filler neck and cap?

ezman

01-20-2011, 08:13 PM

hmmm... that's good to know... didn't really think about fuel actually spilling out. not sure how important it is to have the actual filler neck as the vent. it seems that it would be more of a convience thing. so you don't have to have a 2nd valve to open to relieve the pressure when you fill up.

though i don't think it would be all that bad if you could get a small enough valve that you could tuck into the stock fill location, just need to remember to open it before you fuel up

ezman

01-20-2011, 08:49 PM

fortCollinsZJ

01-21-2011, 12:17 PM

newman98XJ

01-21-2011, 03:56 PM

fortCollinsZJ, do you have any pictures of your setup?

xj9140

01-21-2011, 04:07 PM

please don't drive around with fuel flying from your XJ:shaking:

ezman

01-21-2011, 06:46 PM

if it leaks i'll figure something out. it just doesn't seem like it will. my buddy has his tank strapped down in the back of his tj with the stock filler neck and cap tied up. that thing has been on it's side and lid. no leaks from filler neck at all

Grayguy

03-12-2011, 11:54 PM

Bare with me, I have a lot of pics of my setup. I ended up using a 97' ZJ tank after both my XJ tanks rusted out.

After much measuring and thinking, I pretty much cut out all of the rear floor frOm seem weld to seem weld, and the 22" forward of where the hatch latches. I cut into the seem welds on either side and pounded them flat agaist the frame:

http://i85.photobucket.com/albums/k50/Grayguy/4deef86e.jpg

In the front corner I had to cut into the shock mount ( the ZJ tank is about 3-4" longer than the stock one)

http://i85.photobucket.com/albums/k50/Grayguy/cae8911c.jpg

So I made a patch out of some 1/8" flat bar and marked it out and nibbled it out on our 55ton iron worker :twisted.gif: test fit

http://i85.photobucket.com/albums/k50/Grayguy/3fef40c7.jpg

Welded it In, and then I welded the seam welds I had hammered down against the frame:

http://i85.photobucket.com/albums/k50/Grayguy/f9feb3a9.jpg
http://i85.photobucket.com/albums/k50/Grayguy/ace1762e.jpg

I wanted to put the tank about half way through the floor, which meant that the tank would have to sit about 2" below the frame rails. I went and picked up a section of 2.5" x 1/8 square tube to use. The 2.5" matches the width of the frame rails almost exactly. So tonight I got most of the frame work in and tomorrow I will size the 1/8" plate I'm using for the bottom.

http://i85.photobucket.com/albums/k50/Grayguy/cdb1fac5.jpg

More progress.

Welded the front and rear strap mounts, 1.5" angle with 1/2 nuts welded
To them.

http://i85.photobucket.com/albums/k50/Grayguy/6808298c.jpg

The trickiest part was welding around the hatch latch, the sheetmetal seemed extra thin there.

http://i85.photobucket.com/albums/k50/Grayguy/b66b27ba.jpg

The rear mount didn't seem sturdy enough to me, so I tied it I to another piece of angle that I had already welded to the bottom of the body

http://i85.photobucket.com/albums/k50/Grayguy/3b0cffe9.jpg

Finally, I cut out and welded the bottom piece of the skid.

http://i85.photobucket.com/albums/k50/Grayguy/6e8aae96.jpg

Grayguy

03-12-2011, 11:56 PM

Well after a hecktick week, I got some time this evening to work on it. I got the rear plate and front sheet metal in, and the gas tank perches (a term I just made up) welded up. I'll be putting padding on them so the tank doesn't rub against the metal. As I type this I'm waiting for the cleaning agent to dry so I can primer and seam seal where I need to.

View from the back
http://i85.photobucket.com/albums/k50/Grayguy/55a64101.jpg

View from rear seat.
http://i85.photobucket.com/albums/k50/Grayguy/08448934.jpg

More progress

I plated over the hole in the frame rail that the gas hose passes through
http://i85.photobucket.com/albums/k50/Grayguy/7dd8cc9d.jpg

I chopped most the floor out on the drivers side, it was pretty rotted.

http://i85.photobucket.com/albums/k50/Grayguy/cf3aa5a8.jpg

http://i85.photobucket.com/albums/k50/Grayguy/739f2581.jpg

The underside

http://i85.photobucket.com/albums/k50/Grayguy/e88803d1.jpg

Important progress, popped the window out, figured out the filler neck, bought metal, and built the frame for the box that'll cover the tank.

http://i85.photobucket.com/albums/k50/Grayguy/4814ba4e.jpg

http://i85.photobucket.com/albums/k50/Grayguy/c84b8a47.jpg

http://i85.photobucket.com/albums/k50/Grayguy/48f8c372.jpg

I still need to work out that little corner that's missing, the door wouldn't open with it in place...

http://i85.photobucket.com/albums/k50/Grayguy/093cb964.jpg

That's how it sits now, should be done early this week.

WA-HCRC

03-17-2011, 01:30 PM

this whole thread belongs in the Hack jobs thread :laughing:

Chili Palmer

03-17-2011, 05:21 PM

yeah so after a few minutes of thought. i went and looked at my filler neck and cap. i don't see how fuel could spill out. leak after sitting on your side, sure maybe. but i'm pretty sure the spring loaded valve in the filler neck and the gas cap will work fine for now

Yeah, I have a stock neck and spring cap too. And trust me, it leaks. Even just on winding tight paved turns, people behind me said they see gas spurt out on hard rights. :eek:

There is no question this is going to leak if you don't do something. A buddy of mine moved his TJ filler neck and it is pointing straight up and on a near flop gas came out. He was only on his side for a short time (less than 3 or 4 seconds). With the angle of that tube (20 to 30 degrees?) gas is going to spill out when you go around a mild corner. It might not be much but it's going to happen.

please don't drive around with fuel flying from your XJ:shaking:

This...

ezman

03-17-2011, 11:07 PM

if it leaks i'll definately fix it. i'm just trying to figure out how a pressure system can keep gas fumes in but let liquid gas out?

my buddy has his tank in the back of his tj, sounds similar to what was described. he's flopped it, and it sat on it's side a good half hour with no fuel leaking out.

littlejoe83

04-03-2011, 08:34 AM

Cut the hole (about to the "frame")

http://i1091.photobucket.com/albums/i399/littlejoe29h/657359b5.jpg

Flipped the tank 180

http://i1091.photobucket.com/albums/i399/littlejoe29h/4fc65d24.jpg

http://i1091.photobucket.com/albums/i399/littlejoe29h/769a0eae.jpg

And added the 1/8 skid plate

http://i1091.photobucket.com/albums/i399/littlejoe29h/4a3daa66.jpg

http://i1091.photobucket.com/albums/i399/littlejoe29h/306626ca.jpg

Chili Palmer

04-03-2011, 01:53 PM

Cut the hole (about to the "frame")

Flipped the tank 180

http://i1091.photobucket.com/albums/i399/littlejoe29h/4fc65d24.jpg

Any issues with flipping the tank 180, wiring, plumbing, etc? I need to flip mine and just curious what I'll need.

Thanks.

littlejoe83

04-03-2011, 08:32 PM

U will need some 90's for the fuel lines but other than that u will be fine

GreatWhiteXJ

04-30-2011, 06:24 AM

I dont think I did anything too diffrent from anyone else but...

Cut a hole and moved it up. I wanted a skid to be perfectly flat with the bottom of the frame so I used 1" flat strap to build up a "lip" if you will. Then I put the gas tank in, and marked the angle on the tank in relation to the frame. Then I cut that angle and skidded.

This pic shows the angle of the tank skid...

http://i708.photobucket.com/albums/ww81/JeepinGuy10/013-1.jpg

This is a top shot. You can see the "lip" I made, which worked great as a strap mount to. The straps are simply factory ones that I cut and reformed. And the filler neck attached to a tab on the cage.

http://i708.photobucket.com/albums/ww81/JeepinGuy10/030.jpg

littlejoe83

04-30-2011, 06:44 AM

Update
Hold downs (stock ones just modified)

http://i1091.photobucket.com/albums/i399/littlejoe29h/9ac981dd.jpg

http://i1091.photobucket.com/albums/i399/littlejoe29h/3025ae5a.jpg

http://i1091.photobucket.com/albums/i399/littlejoe29h/c3360162.jpg

I used the plastic tank liner to buffer the tank, cut off the end to go over the top

http://i1091.photobucket.com/albums/i399/littlejoe29h/f255b58e.jpg

http://i1091.photobucket.com/albums/i399/littlejoe29h/79211589.jpg

GreatWhiteXJ

04-30-2011, 06:52 AM

Joe, You ran your straps exactly like me. But backwards....:laughing:

To each there own.... :flipoff2:

littlejoe83

04-30-2011, 07:05 AM

Joe, You ran your straps exactly like me. But backwards....:laughing:

To each there own.... :flipoff2:

Haha well I had to because my tank is fliped 180 :laughing:

XJsavage

05-23-2011, 08:22 AM

Built this bolt on cover for tank protection and for storage...
http://i552.photobucket.com/albums/jj335/jrhxj1/SU1HMDAxMjgtMjAxMTA1MjEtMTkxNC5qcGc.jpg

http://i552.photobucket.com/albums/jj335/jrhxj1/SU1HMDAxNDAtMjAxMTA1MjMtMTAwNi5qcGc.jpg

P1atinum

05-27-2011, 06:51 PM

Same as most others, I dropped the tank and cut the floor.
http://img.photobucket.com/albums/v332/p1atinum/Stage%201%20build/IMG_9190.jpg
I had a Skid Tank I made and was using.. The skid was mounted to the bottom of the sub frame, the plan is to drop the skid in from the top and use it to support the tank using straps on the top. I had to cut some relief cuts in the skid as the sub frame narrow as you move forward, the cuts will allow the sides of the side to bend in slightly.. Once in I will weld it to the sub frame
http://img.photobucket.com/albums/v332/p1atinum/Stage%201%20build/IMG_9194.jpg
http://img.photobucket.com/albums/v332/p1atinum/Stage%201%20build/IMG_9195.jpg
I am going to keep the stock fill location even though a full tank could leak back out the vent and cap. I Still have to weld it all in and strap it down.
http://img.photobucket.com/albums/v332/p1atinum/Stage%201%20build/IMG_9196.jpg
The skid was raised about 6 inches in total. I hope enough clearance for the 14 bolt and 4 link.
http://img.photobucket.com/albums/v332/p1atinum/Stage%201%20build/IMG_9197.jpg

JDL

06-24-2011, 02:04 PM

I wanted to move mine up above the bottom of the frame rails but still mount from underneath.
First I made some room.
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110430_160624.jpg
Then I bent some 1 5/8 tube and added some sheet metal
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110513_222131.jpg
I removed the original gas tank mounts from the floor of the cut out section.
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110514_144204.jpg
welded those to my tube frame for the tank
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110514_153624.jpg
Added the mounts to hold the original straps
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110520_234306.jpg
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110520_234319.jpg
Ended up like this
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110618_135100.jpg
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110618_135134.jpg
finished up inside the jeep
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110621_183215.jpg
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110621_183224.jpg

DeftwillP

06-24-2011, 09:32 PM

I wanted to move mine up above the bottom of the frame rails but still mount from underneath.

finished up inside the jeep
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110621_183215.jpg
http://i1183.photobucket.com/albums/x462/Asher_mich/IMG_20110621_183224.jpg

Cleanest tuck I've ever seen. Kudos.

littledeviltj

08-25-2011, 08:16 PM

I cut a hole in the floor, made a frame with angle iron, used original metal straps. I flipped the tank 180. I cut the existing plastic skid plate to keep the straps from rubbing the tank raw. I think it turned out ok, this was my first time welding to the body and it was fustrating, not to mention I was using a stick welder.

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNDUuanBn.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNDguanBn-1.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNTIuanBn.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNTAuanBn.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNTMuanBn.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNTQuanBn.jpg

littlejoe83

08-25-2011, 09:56 PM

[QUOTE=littledeviltj;13292227]I cut a hole in the floor, made a frame with angle iron, used original metal straps. I flipped the tank 180. I cut the existing plastic skid plate to keep the straps from rubbing the tank raw. I think it turned out ok, this was my first time welding to the body and it was fustrating, not to mention I was using a stick welder.

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNDUuanBn.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNDguanBn-1.jpg

http://img.photobucket.com/albums/v260/sta666TJ/XJ%20build/utf-8BSU1BRzAyNTIuanBn.jpg

Nice work looks just like what I did

proskier101

08-26-2011, 10:50 AM

It isn't pretty but I haven't had a ton of time to work on it.

http://i28.photobucket.com/albums/c240/sproskier101/XJ%20Project/Picture019.jpg

The clearance.

http://i28.photobucket.com/albums/c240/sproskier101/XJ%20Project/Picture017.jpg

I just cut a hole in the floor big enough for the original gas tank skit to fit into. the I just sat the tank inside it. As of now ratchet straps hold it down, but I will be reusing the original straps at some point to hold it there.

http://i28.photobucket.com/albums/c240/sproskier101/XJ%20Project/IMAG0083.jpg

WJJEEPIN

08-27-2011, 10:22 PM

cut out the spare tire carrier.
http://i133.photobucket.com/albums/q51/btwnmak/Jeep%20Gas%20Tank%20Lift/IMG_0422.jpg
Trim about 9" out of sides of gas tank skid. and weld back up. Cut a hole out of unibody and run lines through it.
http://i133.photobucket.com/albums/q51/btwnmak/Jeep%20Gas%20Tank%20Lift/IMG_0428.jpg
Ran a piece of 1/4 steel with a ubolt through the center for a spare tire hold down.

WJJEEPIN

08-27-2011, 10:24 PM

http://i133.photobucket.com/albums/q51/btwnmak/Misc%20Jeep%20Pix/MALL%20CRAWLIN/IMG_0039.jpg
Some Diamond plate cut to seal it up.
http://i133.photobucket.com/albums/q51/btwnmak/Jeep%20Gas%20Tank%20Lift/fd91103d.jpg
Lil dinamat for sound
http://i133.photobucket.com/albums/q51/btwnmak/Jeep%20Gas%20Tank%20Lift/7e8a8654.jpg
Intsalled with ubolt through
http://i133.photobucket.com/albums/q51/btwnmak/Misc%20Jeep%20Pix/MALL%20CRAWLIN/IMG_0048.jpg
And used the bracket from a Yakima roof tire tied down to hold the tire in.
http://i133.photobucket.com/albums/q51/btwnmak/Misc%20Jeep%20Pix/MALL%20CRAWLIN/IMG_0051.jpg
No more saggy diaper
http://i133.photobucket.com/albums/q51/btwnmak/Misc%20Jeep%20Pix/MALL%20CRAWLIN/IMG_0573.jpg

Chili Palmer

08-28-2011, 12:27 AM

Well done, looks clean.

SheetMetalSlug

11-23-2011, 07:05 PM

bringin this back to the top

im using a 12 gal. RCI cell behind the drivers seat, as low as possible.

cut out the rear seat bulkhead and ground it down
http://i664.photobucket.com/albums/vv10/xjmonkey/project%20flex%20j/DSCI0008.jpg

start of the fuel line access
http://i664.photobucket.com/albums/vv10/xjmonkey/project%20flex%20j/DSCI0009-2.jpg

mocking up the tank, need to work the floor some more for the sump
http://i664.photobucket.com/albums/vv10/xjmonkey/project%20flex%20j/DSCI0011.jpg

using a stock xj fuel pump mounted externally
http://i664.photobucket.com/albums/vv10/xjmonkey/project%20flex%20j/DSCI0012.jpg

thats as far as i got today

cj7on44's

01-21-2012, 06:23 AM