Yesterday I found out that the fuel tank supplied was...
...the wrong bloody one!
No problem I thought, just cut the neck of the old tank and weld it to the new one.
Nope the fuel injection pump and sender unit is mounted between two and three centimeters lower and...
..the carb' sender unit sits too high on the new tank.
Plan B. If the new tank came with a gasket I'd be able to make an adapter plate to fit the new take with a neck for the carb' sender unit to sit properly.
It didn't.
Plan C. Weld the neck on.
First I needed to remove the carb' sender unit mounting plate. The best way to do this is to cover the spouts and holes...
...fill the tank with water...
...and use a low speed grinder to cut the mount out.
Trimmed cleaned and flapped ready to use.
Next I needed to make a plate for the new tank...
...mark where the hole needed to be for the neck...
...cut it out and clean it ready to weld.
An inch of plate was formed around the hole and seam welded into place...
...so now the carb' sender unit fits perfectly.
Wouldn't it have been easier to cut repair panels from the new tank to fix the old one?
No...
...it was mostly fiberglass filler, black silicone and waxoil. :bang:
On a lighter note.
These...
...antique 40/45W bulbs have been replaced with...
...these 55/60W P45/H4 conversion bulbs so hopefully my headlights will be brighter than a full Moon when the van is back on the road.
Now I'm off to finish the tank and weld a bracket to it for the new fuel pump.