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Join Date: May 2001
Location: Anchorage, Alaska, USA
Posts: 857
fuel tank modification....

I removed the fuel tank to reconfigure the fill spout so that it will resemble the type used in early vw's, under the hood type. I am wondering if anyone else has done this and if so maybe you could reply with pictures.
The main reason for doing this is to reduce weight and I must admitt the left front fender looks pretty sleek without the fuel door. Thanks if advance.

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1977 911S...sold; 03 F20C; 2009 VW Jetta Sportwagen
Old 12-30-2003, 10:08 AM
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Location: Michigan
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Be sure to wash the tank out with Biosolve before you start to weld on it.
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Old 12-30-2003, 10:12 AM
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Here is my latest work.

ST Project: A hole in the hood part II!

Sounds like you want to do something similar without the hood fill. Just make the neck shorter. I have a "le mans" style flip style filler neck that takes a 2" opening. Similar to those used on the 550 spyder. You can have it if you want. I was going to use it in the trunk and then went with the hood fill.

Fabbing this under the hood will not require a seal and drain.

Just cut off the old filler neck and weld a patch over it. Make sure to take the necessary precautions when welding the fuel tank. Make sure there are no vapors left. Flush several times with water and then blow dry with lots of air. you can hook up a shop vac to the neck and remove the sender unit.

Oh yeah... The fender does look sleek without the gas flap there.
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Old 12-30-2003, 10:34 AM
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Join Date: May 2001
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Jamie, thanks for your reply, pictures, and your offer. I am going to try and use the existing filler neck and cap-somewhat modified of course. The tank is out and the condition is fairly decent compared to some I've seen. Welding will be done by a shop that I use locally.

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1977 911S...sold; 03 F20C; 2009 VW Jetta Sportwagen
Old 01-03-2004, 09:12 AM
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