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Fifth Horseman

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Discussion starter · #1 ·
So I had a bit of a jack stand disaster and my fuel tank, which i just had down for replacing a fuel pump, i now have to take down again because my spare jack went through it when one of the supporting jacks levers broke. Luckily i was not under the car (i think my guardian angel was looking out for me). Long story short my gas tank is broken way beyond repair.

I am very frustrated with the car right now do to some previous issues and some long term issues made worse by my very tight budget right now. I get free stainless flat stock from my work is there any way i could weld up a new small gas tank and just extend my wiring harness and drop my fuel pump and junk into the new tank?

As i recall from taking it down, other that the fuel reset module and the pump i dont rememember any other lines going to the tank.

What kind of unforseen problems am i looking at here, if there are any?

Any thoughts, (or prayers with my luck i need it) just let me know
 
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#3 ·
I feel you man, when budget is tight and the damn car just won't cooperate, best thing to do would be going to your local pick n pull and look for a fuel tank.


I have a fuel tank laying around and I would totally give it to you for free, but I live outside USA.
 
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#4 ·
A lot of power adder guys (including me) ditch their stock fuel tank for baffled cobra tanks. Most people throw away the stocker, but there may be some that still have theirs and will be happy to give it away for free.

BTW, I've been shopping for a new floor jack. Can you tell me which one failed so I can cross it off my list?
 
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Discussion starter · #5 ·
it wasnt the jack that failed the jack stand did it was a autocraft one. i checked invs of junkyards by me and came up dry. oh well i guess i will just fab one up it might look really good in the trunk
 
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#7 ·
i saw Ellicott City and thought the OP might have been a local... i'm not help i guess.

but to TonyG i have been using a Pittsburgh low pro jack for quite some time and have had no isses at all. people usually say harbor freight tools are cheap junk but for things like jacks i have had no issues. my Corrado VR6 Turbo was so low that i still needed a friend to grab the fenders and lift up on the car to get the jack under... used it to get both of my Corrados on stands, a 944 Turbo, 93 Corrado VR6T, my 13 Silverado, my 13 Charger RT, a 13 Challenger RT just to name a few, never an issue

Floor Jack With Rapid Pump®, 2.5 Ton Heavy Duty Steel

again, sorry to the OP for not being much help... i would troll craigslist though. here's just a few seconds of looking

SN95 AND NEW EDGE (UPDATED WEEKLY) a lot of MUSTANG PARTS

is the V6 tank different?
'99-'04 v6 Mustang partout

COMPLETE RUNNING 99 mustang V8 PARTING OUT

99 04 Mustang 3.8 part out

..even found some stuff i wish i could grab for my own project haha
 
Discussion starter · #8 ·
i got the harbor freight low pro jack too. its a nice jack it even has grease fittings for all the joints. its a bit heavy but nothing crazy
 
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Discussion starter · #10 ·
Did some math and measuring came out with a 20l x 10h x 12w tank will give me 10.4 us gallons not including the loss of volume from the pump and my fixtures i will be installing inside of it. So given that information it would probably be better to make it 24l x 10h x 12w. This accounts for the above variables and idea of never actually filling the container all the way "full".

Step 1:
My plan as of right now is to use my works diamond plate instead of the stainless because it is much lighter, put it in our bender and make the 4 bends in it weld up the joint, then cut a top and bottom piece, plasma cut my ring out for the factory fuel pump and hat and one for a aftermarket vented fill port. Need to put metal restraints in the tank to keep the pump from moving, weld the bottom to the walls then the top and then weld 8 angular tabs (2 for each side) for mounting in the trunk.

Step 2:
Should involve plasma cutting a whole in the trunk well so i can run my new fuel line to the filter and have a spot to bring my new wiring into the trunk.

Step 3:
Extend wiring harness into trunk and hook it to fuel pump, mount the pump, test it and win.

Step 4:
Drink cold beer

Atleast this is how it plays out in my head seems very simple, the only think i am really worried about is extending the wiring harness. fabing the tank will not take long at all, im used to doing stuff like this on a regular basis for our ice machines.
 
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#12 ·
JustinG60 said:
but to TonyG i have been using a Pittsburgh low pro jack for quite some time and have had no isses at all. people usually say harbor freight tools are cheap junk but for things like jacks i have had no issues. my Corrado VR6 Turbo was so low that i still needed a friend to grab the fenders and lift up on the car to get the jack under... used it to get both of my Corrados on stands, a 944 Turbo, 93 Corrado VR6T, my 13 Silverado, my 13 Charger RT, a 13 Challenger RT just to name a few, never an issue

Floor Jack With Rapid Pump®, 2.5 Ton Heavy Duty Steel
Click to expand...
Thanks Justin, I've been considering HF jacks. I really liked the extra-long low profile jack, but that one weighs 100lbs. Too bad there isn't an Aluminum version.
 
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#13 ·
Fifth, can't wait to see it. basically building your own fuel cell then eh? just uh, don't let the state smokeys see it, not sure that's DOT approved haha oh... checking for leaks like 16 or 17 times might not be a bad idea either

...Tony, yeh, i digress, the bastard is heavy. "the weight it a sign of reliability." on the upside though, the wheels/casters actually work pretty well. i don't think i have ever had it get stuck on a rock and make me nerd rage into a murderous rampage haha! shameful, but i once threw a wrench at the fender of my Audi TT Quattro over a jack getting stuck on a rock and causing me issues with the suspension work i was doing haha ...not very proud of that moment in time. had to look at the dent every day until i sold the car (driver side)

*sorry for the thread jack there*
 
#14 ·
JustinG60 said:
...Tony, yeh, i digress, the bastard is heavy. "the weight it a sign of reliability." on the upside though, the wheels/casters actually work pretty well. i don't think i have ever had it get stuck on a rock and make me nerd rage into a murderous rampage haha! shameful, but i once threw a wrench at the fender of my Audi TT Quattro over a jack getting stuck on a rock and causing me issues with the suspension work i was doing haha ...not very proud of that moment in time. had to look at the dent every day until i sold the car (driver side)

*sorry for the thread jack there*
Click to expand...
[/continue threadjack] Yeah I may get that one just for home use, and a lighter Al jack for trips to the dragstrip. I look forward to the low-profile jack. My other car is an R32, and I need to drive onto wooden planks before I can put a jack underneath. I can relate to the violent outburst. I once punched a hole in my garage wall after I broke my timing cover [/end thread jack]
 
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Discussion starter · #15 ·
JustinG60 said:
Fifth, can't wait to see it. basically building your own fuel cell then eh? just uh, don't let the state smokeys see it, not sure that's DOT approved haha oh... checking for leaks like 16 or 17 times might not be a bad idea either

...Tony, yeh, i digress, the bastard is heavy. "the weight it a sign of reliability." on the upside though, the wheels/casters actually work pretty well. i don't think i have ever had it get stuck on a rock and make me nerd rage into a murderous rampage haha! shameful, but i once threw a wrench at the fender of my Audi TT Quattro over a jack getting stuck on a rock and causing me issues with the suspension work i was doing haha ...not very proud of that moment in time. had to look at the dent every day until i sold the car (driver side)

*sorry for the thread jack there*
Click to expand...
Yea basically a fuel cell, but completely tailored to the volume i want and set up for a return-less fuel system like our cars have. I tried working with the diamond plate today and gave up, the composition of the metal was really cheap and became to brittle after welding, I started on my stainless one, it is going good so far, i just wish i could have made it lighter.

I will try to get some pictures up after the weekend when i have more time to play with it.

state smokies can kiss my ass they need to learn to quit infringing on peoples personal freedoms.
 
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Discussion starter · #16 ·
Sorry been very busy lately, i got the metal cut, sanded and its tac welded up, after all the trimming and sanding its not as a heavy as i thought it would be, maby 20lbs for the entire thing, less after i cut the top holes out for the filler and the fuel pump hat. pictures below. Ignore the poor camera quality. The pictures make it look large but its only 22"x12"x10"
 

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Discussion starter · #17 ·
Hey guys I thought I would post back, I completely forgot about this thread but I completed this project a while ago and it went perfectly. For starters I did mount the tank in the trunk and welded it to the spare tire well. I completely deleted the entire EVAP system including the canister all the way up to the plenum in the engine bay. I deleted the fuel neck and all the misc parts to go along with. From my fuel tank i simply have the power harness and a piece of submersible fuel line going to the fuel filter. I made a entirely new pump hold down in the tank with threaded rod and a clamp system so that I could retain the factory sending unit system. I did not have to cut any wires or modify any harnesses it was all plug and play. The car does throw codes for a evap, but they are just a minor useless annoyance. Tuner will be changing the tune to disable the EVAP system

I am happy with my proof of concept idea, but I am not happy with the tank I made. While I can weld decently and the whole tank is perfectly sealed, it looks like a shitty rough job and i would have liked something that was laser welded or tig like a professional. I am also when I start this project for round 2 i will go from a 10 gallon tank to a 5 gallon. The size of the tank while small has not grown on me very well and it will need to be smaller.

Let me know if you guys are interested in anything I did, if you buy a tank it is a very easy install and you throw a ton of weight off the car, unfortunately though it is off the ass end of the car so not exactly best for power to weight ratio.

I will post pics on request, I am embarrassed though of how shitty it looks.
 
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#19 ·
mjackson3010 said:
There is no such thing as beyond repair. U can fix it or junk yard or new or ebay
Click to expand...
I would never repair a gas tank when there are plenty of other options out there.

As said above OP I would have given you mine too. I threw it away. You should be able to find a decent used tank, or check rock auto or something, I don't think the tanks cost all that much.
 
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Fifth Horseman
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