My fuel tank mod

[Sebscst]

I was not happy with the way the fuel tank looks with the spare tire cut out. After looking at many rs and rsr fuel tanks and also fuel cells. I still didn’t like the look or the price $$$. So I decided to cut one up and see what I could do.

First step was to strip off all the Shultz coating. A friend of mine Bob (andoni510) suggested a oscillating tool or multi tool. I happen to have a Harbour freight one I use for work. Well after I think 3 hrs and no feeling left in both hands it was done. Next step was to start cutting.


I couldn’t believe how clean the inside of the tank was. If I had to do it again which I might I would cut it a little different but oh well . I don’t have a tig welder so took it to a dude I know and helped him do it. Everything was good but the top did buckle in one stop. The important thing was after pressure test no leaks.


Next came the filler to make it look decent. Bondo is like drywall mud anyone can do it but it takes skill in order to have less sanding. I don’t have those skills. Break out the 40 grit and shape it.



Happy with it so far,not perfect but hey it’s a fuel tank. I wanted to finish it with a slight texture and something durable. I decided to use spray on bed liner from rust oleum. There’s a really good YouTube comparison of all the different bed liners and this one suited my application.


This is after one coat. I’m going to let it dry and add another coat. You can still kind of see were the top pieces meet at certain angles but from looking at it from the top it looks good. I like it better than anything I could have bought and at least it’s one of a kind.

[Techno Duck]

How many gallons is the tank now?

[Sebscst]

No idea I just literally finished it 15 minutes ago.

[manbridge 74]

I will guess 26 gallons...

Looks good.

[tperazzo]

Cool man! Did you do anything special to purge gas fumes before you cut into it? I want to drill into mine soon, but don't want it to explode. It's been empty for years, so I guess it's safe but I thought I would ask anyway. My plan was to fill it with water and then cut with air tools??

[GH85Carrera]

Originally Posted by tperazzo

Cool man! Did you do anything special to purge gas fumes before you cut into it? I want to drill into mine soon, but don't want it to explode. It's been empty for years, so I guess it's safe but I thought I would ask anyway. My plan was to fill it with water and then cut with air tools??

Just point the exhaust from a car into the gas tank for long enough to make the tank warm. An old car with lots of carbon monoxide is best for that. Use a tube to connect them and do it outside.

[Sebscst]

Just fill it with water and let it run through it for 5 min. I’ve welded lots of used tanks before and never had any issues.