Outer Limits 4x4 Board

I just went and got a price on a replacement fuel tank for my sierra and they want almost $300!!! And that's a second hand one...
The seam in mine looks like it is falling apart and leaking a fair bit of fuel (didn't have time to pull it out on the w/e) and the spare tank out of the parts car has about 15 puttied up holes in the bottom of it. Are the seams repairable? Or is it possible to make a fuel tank with a few DIY skills? I'd rather make one for a $100 and a w/e's work than get robbed buy a wrecker!

Probably cheaper for you to get one over here!

I got a rare as hens teeth coily tank (for my efi) for $100 8mths ago. And a 50L efi vit tank for $110!! Suzifour at Dunheved.

Hmm suzi's and parts always seem alot more expensive over here than over east.

i got a standard, undinted one in my shed that could use a new home. depending on frieght it should still be cheaper.

Kitika - try www.suzistore.com.au - they sell new and wrecked.

So other than standard what other tanks are an easy replacement for a SWB Sierra? Mines completely stuffed and need to replace. I want to get a bit more fuel carring capacity without having to spend BIG dollars on a longrange tank. Thanks...

i havent got that far yet but want to look into custom made tanks... legalities would be the issue i spose.

i know few people have cut, extended and shut their stock tanks before without issues (although not not about issues with the law).

petroworks i think it was made tanks in the USA to suit zuks (clear ones too!) not sure on shipping cost though.

The coily tank that i bought, It was perfect, until i bashed it again..So now I have done a 50L EFI Vit tank 2weeks ago. Should of done it earlier!

I have a 2"BodyLift.

I cut all old mounts off, including exhaust bracket. The tank almost fits in perfect bolting to the original chassis rear crossmember. With some slight hammering of the body in spots to clear the fuel pump and other outlets it does fit perfect!

My front mounts for the tank had to be bolt on as i had no welder at home, so i made some mounts that bolt into the original holes for the front of the tank.

The original hose was stiff as, so i had to cut and extend parts with pipe so now it fits fine..

I also made a full guard while the tank was out and empty to boltup with the tank. I will probably never hit it again as it is much higher, but if i do its guarded!

This probably should be in a vitara tank subject..

BlueSuzy wrote:I also made a full guard while the tank was out and empty to boltup with the tank.

Hope you didn't leave a gap between the guard and tank. Ive see a tank rubbed through with a stone lodged between the guard and the tank body.

Hard to know how lon it had been rubbing away but not fun - by the time the guard was removed the full tank of fuel had been lost and we were in central nowhere so its created an issue.

A sheet of polystyrene foam or spray expanding foam is a great "insurance policy" IMO.

MightyMouse wrote:

BlueSuzy wrote:I also made a full guard while the tank was out and empty to boltup with the tank.

Hope you didn't leave a gap between the guard and tank. Ive see a tank rubbed through with a stone lodged between the guard and the tank body.

Hard to know how lon it had been rubbing away but not fun - by the time the guard was removed the full tank of fuel had been lost and we were in central nowhere so its created an issue.

A sheet of polystyrene foam or spray expanding foam is a great "insurance policy" IMO.

Good idea MM, it may also drop the noise down off rocks hitting the bash plate.

Kitika - my last one cost $50 but was off the forum, 2nd hand.

I have a coily one - in my coily surprise surprise.

However, it has been absolutely pounded. The bottom of it has been bashed by countless rocks. I am really surprised it hasn't been punctured.

I am sure I would get an extra 5-10 liters if it was in better shape.

Has anyone successfully separated the tanks at the seams, straightened em, and got em back together leak free?
Any special tricks?
How is the seam fastened from factory? crimped and spot welded or?


One of my old bosses from a long time ago used to solder fuel tanks with some sort of mesh stuff, and a massive soldering iron he would heat up with an oxy on the other side of the workshop.

you can blow the tank out, but this can cause a leak... use high pressure air, put it in the filler cap, wad it up with rags etc so its as airtight as possible and let the air rip... its 50/50 if you'll crack the tank on a dent though. Pretty sure nicbeer has done it succesfully in the past?

alien wrote:you can blow the tank out, but this can cause a leak... use high pressure air, put it in the filler cap, wad it up with rags etc so its as airtight as possible and let the air rip... its 50/50 if you'll crack the tank on a dent though. Pretty sure nicbeer has done it succesfully in the past?

Yep done it on the old zook sucessfully.

I think it made it slightly weaker so it dented easier afterwards but it worked

Use some kneed it to bog it up

Or get one off Ebay for no more than $50- if someone is selling them.

I got quoted $1070- from ARB last week to put in a long range 70L tank!

Good thing I didn't cause my Zooks engine died last Friday!

MightyMouse wrote:

BlueSuzy wrote:I also made a full guard while the tank was out and empty to boltup with the tank.

Hope you didn't leave a gap between the guard and tank. Ive see a tank rubbed through with a stone lodged between the guard and the tank body.

Hard to know how lon it had been rubbing away but not fun - by the time the guard was removed the full tank of fuel had been lost and we were in central nowhere so its created an issue.

A sheet of polystyrene foam or spray expanding foam is a great "insurance policy" IMO.

Yes i did leave a gap!
But its a gap right through! about 20/25mm
The reason was for mud and rocks to escape either end of the guard

1070 for a 70L tank.

Ouch.

what about just finding a tank from another vehicle. As long as dimensions are the same or will fit in the space and as long as you can hook it up can't see any dramas.