Yesterday I finished cleaning up the used tank. I had been doing the white vinegar & stainless steel nut/washer 'shake and sit' routine. When I finally poured out the vinegar I was pretty amazed at how much rust came out of the tank. I was afraid to see what was left in the tank. Once I looked inside with a flashlight, I was really pleased with the results! Based on what I saw I went ahead and poured in a mixture of water and baking soda to neutralize the acid. I sloshed that around for a bit and then rinsed the tank out a few times. From there I poured a bunch of WD-40 in the tank and made sure I coated all the inside of the tank. From there I ran it down to the muffler shop to have them weld the neck back on. They did a great job! I put a quick coat of primer and paint on the tank to make it look good again. With all that work done, I woke up this morning took a crack at installing the right hand tank. All in all it was pretty straight forward. I took some photos along the way.
First thing I did was take a look at the left tank to try and get an idea of how things would shape up:
Step1.jpg
From there I loosened up the 1/2" nut that was securing the top and bottom straps. With that loose I removed the gas cap and slid the left tank to the right and into the trunk. I loosened the hose clamp on the fuel line and removed that. I quickly plugged the hole with my finger and slid everything out of the trunk. From there I took some masking paper made a template of the existing hole:
Step2.jpg
I took the template from the left side and flipped it over. I carefully aligned it on the right side with the mirror image of several reference points I marked from the left side. With the template in place I stepped back measured things again. I then marked a 2 3/4" hole I had transferred from the other side. I then sat down and drank a beer and took a deep breath. I then lined up a 2 1/8" hole saw right in the center of the 2 3/4" hole I had previously marked (this left room to move and adjust if necessary):
Step4.jpg
Once the hole was cut there was no turning back. I eyeballed the base bracket in place and tried to offer up the right tank. Things looked close so I did the enlarged hole a little bit at a time. Offering up the tank after every few minutes to make sure I was on the right path.:
Step5.jpg
I pulled the tank out one last time and installed the base bracket, the top strap and bracket, the bottom strap and bracket. With all of those in place I tightened everything down and made sure the neck had a good 1/8 gap evenly all around it. I marked where I needed to enlarge the hole. I removed the tank and then carefully enlarged the hole to keep everything even. Once done there... I took a step back and drank another beer:
Step6.jpg
The last step was to offer the right and left tanks back into the car one last time. I then installed two new filler neck grommets and then tighten everything down. I installed the new Y pipe, fuel lines, and the new stainless steel vented caps.
Oh, another thing I did today was install some dynamat underneath and behind the rear seat. This helped a bit with the drone from the exhaust / road noise.
All in all it looks great. Very pleased with the results. Next project are going to be installing new rear tapered wheel bearings, rear bearing races, and the rear sway bar.
Thanks for letting me share!
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