putting a 21 gallon fuel tank in a '75 CJ5?

[Hedgehog]

I'm installing a 21 gallon fuel tank in my '75 CJ5 . Like most CJ projects what seems like it should be simple or a bolt on item in reality isn't. MY tank is supposed to fit and dimensionally I'm sure it does/will. The problem is, none of the parts supplied to attach the tank to the jeep fit. It could be the fact that the PO modified the rear of the frame. I thought I'd taken care of that issue by cutting off as much of his repair as possible and replacing it with jeep parts.

So, have you actually done this on an intermediate jeep? If you have experience, did you end up fabricating your own parts? It doesn't really look like a big deal, but it's always good to see how someone else tackled the same issue. Thanks.

 

[Woolyworm]

What are you using for a skid? Stock type, 1/4" aftermarket like this from 4XDoctor, or custom? I have a stock 20 that i want to install and will be going with 4XD. My stock 15 is now crushed into about 11 which doesn't go real far with my AMC 304


Wooly

 

[Hedgehog]

I have a stock skid plate that is something the CJ didn't have before. Since the tank was originally a tank for a newer CJ the skid plate is a newer model (which fit the tank). Yes, it is a tank originally designed for a newer CJ, BUT it is listed to fit my '75. The more I look at the tank the more convinced that the solution will be to lift the tank in place, then build/modify the supplied brackets (sheets of galvanized steel) to fit the jeep. That is unless I'm missing something, which is very possible. It would be nice if a product like this came with any sort of documentation on how the install is supposed to be done.

A BIG sturdy skid plate would be nice, actually more than nice. Unfortunately that will have to come later, maybe much later. Even then I'll probably make it myself.

 

[Woolyworm]

Use the force old Jedi....... The way will present itself!


Wooly

 

[Hedgehog]

That's about it .... I'll have to "Use the Force". That just might have to become my motto.


----- Later, yep lifting the tank into place has brightened the situation considerably. Some of the instillation parts won't work, others can be modified to work.

 

[Lumpy Grits]

The only easy day work'n on a CJ, was yesterday(or maybe the day before).

LG

 

[Woolyworm]

That's about it .... I'll have to "Use the Force". That just might have to become my motto.





----- Later, yep lifting the tank into place has brightened the situation considerably. Some of the instillation parts won't work, others can be modified to work.

Glad you're making some progress. I've been putting off doing mine for 2 years now do to pain in the butt factor and $.


Wooly

 

[Hedgehog]

As CJ projects go and if your jeep is unmodified the job is actually fairly easy. All of 3 bolts held mine in place, 2 in the back and 1 in the front. Of course you have to deal with all the rubber connections too. I cheated on mine by simply cutting the fuel hoses and GENTLY removing the fuel filler and filler vent hoses. Fuel lines are fairly easy to find, not so with the filler hoses which are almost impossible to find.

 

[Woolyworm]

I'm looking at about $350; i need the plate and all tank parts since I'm going from at 15 to 20.


Wooly

 

[Hedgehog]

Most of the kits come with the sending unit installed. Interesting in that the 21 gallon pickups don't have a filter inside the tank. They suggest installing a clear inline filter. I pulled the one from my tank and added a stainless steel in tank filter.

WARNING - The thing didn't want to go on and I ended up modifying a filter to fit. I won't tell you how, I think someone else might find a better way.

As far as a skid plate is concerned, I got lucky .... VERY lucky. While going through the bent up used skid plates at Willys Works we came on a brand new one with the stickers still on it. It was in a pile of junk he got from someone and he didn't know it was there. Rob sold it to me as a used item, but I slipped him a little more for it.

All in all you are right, these tanks aren't cheap, but not as expensive as they could be. A friend of mine worked in the marine industry building and maintaining boats. He used a good sized all metal boat tank that didn't cost as much as you'd expect it to. In hind sight I sorts wish I'd gone that route.

Tank nomenclature seems to vary, some sell the tanks as being 20 gallon tanks others (mine included) list their tank at 21 gallons. I'm itching to see how much it will take to fill my tank. Here's a little bit of a disturbing side note. My pick up didn't go all the way to the bottom of the tank, it missed the bottom by about 1". In a tank this size that's a lot of fuel left unavailable to the fuel pump. I dropped mine down some, it's still off the bottom and has a filter on it, but it's deeper in the tank than it was.

 

[Woolyworm]

Right on with the skid!

My understanding from some Limited research is the stock tanks were 20, the aftermarket are 21. I search mine against some numbers stamped into the tank and it's a stock one. There's also a bit of difference in the shape.


Wooly

 

[Hedgehog]

The Fuel tank is finally in the CJ5 , all hung and plumbed, ready for fuel. The axle just went in and is hanging on the springs. Now I'm a little concerned. The differential looks VERY close to the tank. Might even hit. Is this a common thing? Are differentials usually VERY close to these 21 gallon tanks?

 

[hondo]

yes i noticed the same thing with mine. i haven't done any extreme rock crawling but have flexed it out a few times and haven't noticed it hitting. when i can i will make a new skid plate that will fit tight to the tank and allow extra room. maybe even i small body lift so i can shove it up another inch

 

[Hedgehog]

I've got a small body lift, had to lift the tank to make the fuel filler work properly. The skid plate could be a tighter fit too. Maybe a couple ratchet straps would squeeze it enough to weld a strap around the top, kind of a girdle effect. I can see it now, "Look at what the PO did to the gas tank."

A more practical problem, changing fluids might be a chore now. I wish I'd drilled the Dana 44 for a drain plug, removing the cover might be a pain.

 

[Lumpy Grits]

HH-You have never had to drain the oil from a 3/4 ton Ford 9" then.

LG

 

[Hedgehog]

No, no I haven't. I admit to never paying much attention to the differentials on my vehicles before. Relatively speaking this vehicle is far to spoiled.

After work I dropped the jeep down on jack stands under the axle. It's not as close as I'd feared it would be. Except for the "T" end of the tank strap. The darned thing is bent upwards. Tomorrow it's BFH time, that is if a good angle can be gotten on the "T".

 

[Torxhead]

Hedge, have you considered bump stops? I for one would sure would like to see pictures of this mod.

 

[Lumpy Grits]

hedge, have you considered bump stops? I for one would sure would like to see pictures of this mod.

Yes-X2.
LG

 

[Hedgehog]

The Jeep came with about 4" or 5" bump stops which are still in place. If I can bend the "T" tab to ride flat against the skid plate I believe all will be well.

I kick myself because the skid plate did not follow the back contour of the fuel tank very well. About a dozen times I thought about bending the plate to fit, but decided that it would be bad to have gravel and such get stuck between the tank and the plate with no ability to clean it out. Also, surely there wouldn't be a space problem. WRONG assumption! The idea of synch strapping the plate tight to the tank and adding a permanent metal strap does appeal to me.