Mustang Fuel Tank Install (Pics)

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Mustang Fuel Tank Install (Pics)

Postby BobbyFord on Fri Nov 27, 2009 8:40 pm

I used a 1970 Mustang, 22 gallon tank for my swap:
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Fisrt, I made a support frame out of 1" X 1" square tubing:
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Frame was accessed to weld attaching nuts to the inside of the tubing for easy mounting of the tank to the frame:
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The lower lip of the rear frame rail must be masked and trimmed for clearance:
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The crossmember between the rear leaf mounts must be removed and relocated to the rear edge of the frame.
The crossmember must be installed upside-down to accomodate the conture of the underside of the bed:
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Mounting nuts are welded to the crossmember because there is no room to get a wrench inside during assembly:
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The rear hole is for the rear bed mount bolts:
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Tank mounted to frame and installed with crossmember in place:
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The inlet on the fuel tank is not in the exact center of the fuel tank but you will want to center your fuel door hole in the bed for asthetic reasons. Mask and cut fuel door hole in bed:
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I wanted rounded corners on my fuel door, so I took the extra time to weld in some corner pieces and round file them:
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Next, figure out what fuel door hinge you are going to graft in. I used one off of a late 80's Town Car. Fab a support frame to mount the fuel door:
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Next, cut a piece of correct gauge metal and form into a thumb-grab to be grafted to your fuel door:
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Mount your fuel door frame and attach fuel door: (still gotta grind down the spot welds).
I used fuel door bumpers off of an '08 Focus.
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All that is left is to plumb your new fuel line and extend your fuel sending unit wire to the Mustang sending unit (ohm parameters are the same).

:D It's a sickness.
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Re: Mustang Fuel Tank Install (Pics)

Postby td on Fri Nov 27, 2009 9:45 pm

how will you access your bumper bolts when its time to put it on?
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Re: Mustang Fuel Tank Install (Pics)

Postby BobbyFord on Fri Nov 27, 2009 9:50 pm

td wrote:how will you access your bumper bolts when its time to put it on?

Bumper bolt nuts will be welded to the inside of the frame rails so the bolts, from the outside, will be all that is necessary to access.
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Re: Mustang Fuel Tank Install (Pics)

Postby td on Fri Nov 27, 2009 10:33 pm

great idea, good lookin work to  :thup:
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Re: Mustang Fuel Tank Install (Pics)

Postby dantheman71 on Fri Nov 27, 2009 10:53 pm

Nice job, looks good.
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Re: Mustang Fuel Tank Install (Pics)

Postby 91Bear on Fri Nov 27, 2009 10:58 pm

Is there any way to install a fuel filler that is flush with no door?  Maybe a racing type?
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Re: Mustang Fuel Tank Install (Pics)

Postby OldRedFord on Sat Nov 28, 2009 12:50 am

What did you do for a tank cap?

Looks good.
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Re: Mustang Fuel Tank Install (Pics)

Postby robroy on Sat Nov 28, 2009 1:24 am

Hi BobbyFord,

That is very impressive work and excellent photography!  I'm especially impressed with the rounded corners on your filler hatch.  Well done!

Robroy
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Re: Mustang Fuel Tank Install (Pics)

Postby BobbyFord on Sat Nov 28, 2009 11:50 am

91Bear wrote:Is there any way to install a fuel filler that is flush with no door?  Maybe a racing type?

I have seen racing type billet caps for this application, I think the only hassle would be tightening the filler hose clamps with the bed in place.

OldRedFord wrote:What did you do for a tank cap?

Looks good.

I just used the stock cap off of the in-cab tank and the in-cab filler neck shortened down.
robroy wrote:Hi BobbyFord,

That is very impressive work and excellent photography! I'm especially impressed with the rounded corners on your filler hatch. Well done!

Robroy

Thanks, Robroy. It looked weird with the squared off corners, I had to do something.
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Re: Mustang Fuel Tank Install (Pics)

Postby dantheman71 on Sat Nov 28, 2009 12:25 pm

So this is a dumb question, but you made the square frame and bolted the gas tank to it, How did you fasten that square frame to the truck frame? I don't see any bolts through the frame, does it just lay on the bottom lip and you weld it on?
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Re: Mustang Fuel Tank Install (Pics)

Postby BobbyFord on Sat Nov 28, 2009 12:37 pm

dantheman71 wrote:So this is a dumb question, but you made the square frame and bolted the gas tank to it, How did you fasten that square frame to the truck frame? I don't see any bolts through the frame, does it just lay on the bottom lip and you weld it on?


These two bolt holes are at the rear-most two corners of the tank frame and are bolted to the bottom frame rail:
Image

Here is a picture of the tank frame, note the three tabs welded to the front of the frame:
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The tabs bolt to the crossmember in front of the tank as is sits in place. Mounting nuts are welded to the inside of the crossmember so that it is not necessary to try to get a wrench up inside.
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(5) 5/16-18 bolts hold the tank frame to the truck frame. To remove tank frame and tank assembly all you need to do is remove the bumper, remove rear crossmember, remove the (5) 5/16 bolts, raise the rear of the bed and the tank and tank frame assembly will slide out on the frame rails.
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Re: Mustang Fuel Tank Install (Pics)

Postby robroy on Sat Nov 28, 2009 1:52 pm

Hey BobbyFord!  I'll bet if you were to produce a batch of those frames you could sell them very easily!  I'm sure a kit that would help people implement this rear Mustang tank would be very popular.  

But perhaps the time it takes to make each frame would offset the benefits for you?

Robroy
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Re: Mustang Fuel Tank Install (Pics)

Postby dantheman71 on Sat Nov 28, 2009 2:13 pm

It all makes sense now!! Thanks
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Re: Mustang Fuel Tank Install (Pics)

Postby OldRedFord on Sat Nov 28, 2009 9:15 pm

robroy wrote:Hey BobbyFord!  I'll bet if you were to produce a batch of those frames you could sell them very easily!  I'm sure a kit that would help people implement this rear Mustang tank would be very popular.  

But perhaps the time it takes to make each frame would offset the benefits for you?

Robroy



If a guy was to set up a jig to weld up the frames, it would sure speed things up.


Only other thing I am wondering about is what sending unit did you use?
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Re: Mustang Fuel Tank Install (Pics)

Postby BobbyFord on Sat Nov 28, 2009 9:38 pm

robroy wrote:Hey BobbyFord!  I'll bet if you were to produce a batch of those frames you could sell them very easily!  I'm sure a kit that would help people implement this rear Mustang tank would be very popular.  

But perhaps the time it takes to make each frame would offset the benefits for you?

Robroy


I've thought about it, Robroy, but it's time consuming cutting the tubing and welding the nuts inside. I had a plan when I started the fuel tank swap but it changed a bit as I went along and saw what would and wouldn't work. After that I was just fabbing as I went.

OldRedFord wrote:
If a guy was to set up a jig to weld up the frames, it would sure speed things up.


Only other thing I am wondering about is what sending unit did you use?


The Mustang sending unit uses the same ohm parameters as the truck sending unit and is compatible with the truck fuel gauge.
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