So yesterday we got the GenRight
20 Gallon Fuel Tank out and set inside the new frame. It's much clearer now on what modifications will have to occur to get the tank in place. To start the factory Jeep frame bends down after the axles as it reaches back to the rear bumper. GenRight did a great job as this tank fits into the factory Jeep frame without issue; however, with the Throttle Down Kustoms (TDK) the frame continues straight back to the bumper without dropping back down. I believe we will axtend the botton side of the rear crossmember to address not only the 2 7/16" gap on the rear mounting plate but it should help us with the monting of the winch.
In Build 3.0 I ran the dual exhaust inside the frame. This is important to me as I like the look and the clearance. In order to to this we will be inserting a 3" OD .125 wall DOM in the rear frame cross member as well as the body support cross-member. Next, we will modify the top corners of fuel tank by notching out the top 4" (Deep) x 4" (Inward) corners from front to rear. This should give us the room we need to allow the exhaust the space it needs to slip by the fuel tank without causing any heat issues near the fuel. I am assuming we will lose 1 to 2 gallons of capacity. This will create an issue with how the current fuel filler necks work. If I have to I will put a fuel door in the bed of the Jeep but I am trying to keep it DOT legal.
Another concern with doing this is being able to thread the body bolt into the body without the exhaust interfering. We will likely use 2.5" 3 bolt exhaust flange in order to remove the tail section of the pipe to get to the body mount screw.
Has anyone seen this done on a Jeep?
To Do:
- Modify Tank
- Cut in 3" DOM Tubing
- Create a 2 7/16" spacer to mount the bottom of the fuel tank to the frame and support the forward bolts on the winch.
- Modify rear-exhaust pipe so it can be removed.
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