Having bought the worlds worst designed kit car over a year ago I have slowly gone through trying to rectify every design fault including lopping off the front suspension and starting again...

But im having an issue with the fuel tank..


Its a thin stainless steel jobby....The sender sits in one end just fine...but the other end where the inlet is suposed to be is just a 2.5" hole....


Somehow I need to perminatly attach a bit of pipe to the fuel tank so my inlet flexi can connect to it..


My initial thought was to get a stainless plate, cut a hole in the middle of it and weld on a suitably sized tube to take the inlet flexi....And then use some kind of fuel resistant glue to bond the plate to the top of the tank..... Would this be acceptable? and are there any fuel proof mastic sealants?


Idealy I would rivot the plate to the tank but as the tank is already embedded into the car with some fuel in it I cant risk drilling holes in the tank and getting stainless swarf into the fuel system.....

Anyone have any cunning thoughts appart from torching the entire car and starting again?

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Originally posted by tegwin
My initial thought was to get a stainless plate, cut a hole in the middle of it and weld on a suitably sized tube to take the inlet flexi....And then use some kind of fuel resistant glue to bond the plate to the top of the tank..... Would this be acceptable? and are there any fuel proof mastic sealants?

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Im still going to have to drill holes in the tank to take the self tappers though which brings me back to the issue of swarf in the fuel

I would pull the tank out empty it and steam clean or water fill before attempting to drill, when cutting and drilling my stainless tank I got heating and sparks not to mention a fair few broken HSS drills!

Caber

I found a flanged 2.5" tank connector and made up a C shaped plate to go inside the tank. welded six bolts to it and drilled holes in tank and flange, like drawing. You will still have to take the tank out and clean it.
Rescued attachment tankconect.jpg

Spoon covered in grease under the hole you are drilling will do the job.

Then use cheap £1 disposable filter just after the tank and throw it away and replace after a ew hundred miles.

Pat...

I think the Robin Hood tank is designed to use the Sierra tank filler tube & rubber seal (still available from Ford). Fits quite well on my S7 .

Strangely the fuel sender won't fit - the studs are too short and in the wrong place. guess you get one good hole on each tank

dont' know about the rh design, but have done the tank on a sierra and the rubber does just push in and is then held in place by the filler spigot which shoves inside it, so should work ok.

buy a new ford rubber and they will seal
you can also make a spacer to make the tank a little thicker and use the old seal... mine lasted a long time like that

dave