As the fuel tank in my Dodge didn't want to hold fuel in anymore I'm going to make one from scratch.

The tank I had in the wagon was from a 60's british ford car and only held 8 gallons (UK ones as if that makes any difference) so the range of driving was about 100 miles then I had to find somewhere to fill up again. I've known this day would eventually come and a while ago Aaron (C-300) kindly took a few dimensions when the tank was out of his lovely Polara which gave me something to go on but due to the awkward shape and where it fits I had no option but to start making some sort of template that could be copied and eventually made in steel.

I've almost completed a wooden box template which when I'm done I could use a a rabbit hutch lol. The big question is what thickness steel should I really be making it out of?

Also is anyone familiar with dodge trucks DT 61-68? I can get my hands on a sender Mopar part No 2240725 and I'm wondering if the resistance would be similar enough for the wagon's gauges? http://www.nosmopar.com/query.asp?make=mopar&year=0&section...

Carl

I've made a start

was tricky not having a proper tank to start with so had make something fit which I could hopefully copy

Here's the wooden pattern I made.

I started sticking some metal together and this is how far I got last night.

The jeep sender was no good as the resistance was 200ohms so I went for the dodge truck sender a seller had in the UK for £35 and that's spot on!

Well after a few weeks of evenings after work and a few lost weekends......

 Just a few tacks and sides..

Lucky these welds are in the inside...

Grind off and fins some holes...

Must learn to let go of the torch and stop getting it all too hot...

I have my moments...

The state of the floor afer grinding, and cutting...

Whoops that bit is supposed to be on the inside..

Like that..

sender Reinforcing plate witha section cut out so it can fit through the hole from the outside in..

Made a sleeve with a groove ot fit a nitrile O-ring that the filler neck can push in and seal.

Trying to get the position of thsi correct was a task..

Eventually got there..

Baffle...

Front baffle with slot cut to allow sender float to travel..

Baffle welded in..

Fuel pick ip pipe..

Drain plug..

Now it's test for leaks time..

 After a couple of days of pressurising and finding leaks then releasing the pressure to weld up the holes the test again was getting a but tiring. Eventually got to hold 8-10 psi without blowing bubbles..

A but of clean up and paint..

Here is the tank it replaced..

And in!!

89 litres, 19.6 gallons, 23.5 U.S. Gallons. Not far off I beleive!!