Reproduction fuel tank, what fit issues?

[Dublinoh]

Hi I am in the process of replacing a fuel tank on a 1987 Carrera. I plan to order a reproduction from this site.

Does the one sold now still have fit issues?

What was the area that gave problems?

I am a hobbiest/mechanic ie limited skills...should I be able to get this to fit properly?

Any input on this project would be appreciated...thanks Joe

[BoxsterGT]

Free bump!

I would like to know too.

Len

[Justin@Athens]

I just went through this--but ended up just boiling and resealing mine instead. The issues with the repro tanks generally are in regard to the angle of the filler neck, however i have read a thread where at least one user here had problems with the port for the sending unit being too small as well. I have some suggestions for you if you just have a small leak--or even a moderate amount of rust around the tank half seams.

[JP911]

I bought a repro and had issues with fitting the sending unit. The studs on the tank did not line up with the holes on the sender. I had to open up one of the holes to get it to fit. No issues getting the filler neck to line up.

[Dublinoh]

I asked when I ordered my repro for 1987 carrera, he said the fit issues were with the early tanks. Still waiting for delivery and then paint. I will post any issues after the install. Ordered from our host FYI.

[Won]

I have one from about 3 years ago. Everything fit well except for the smaller diameter vent line fitting going from the tank to the plastic canister halfway along the filler tubing. The angle of the vent fitting was wrong so the original tubing was too short to reach. It was a simple fix and it's been working pretty well.

[Dublinoh]

I installed the tank today, I had the tank coated with the Line-x epoxy paint. Has a very nice texture and the gray color I ordered looks stock. The tank was shipped with a fuel filter, an agent from our host told me it was just a shipping plug. However the screen area was ripped in several areas, so I installed my original. The seal o-ring looked a little different on the supplied filter...a little worried about leaking there, I used a new seal for the original filter, and I have not added gas yet so we will see.

The Line-x added to the dimensions and at first the tank would not seat. Removed the coating on the passenger side on the outside of the seam in front of the clip that holds the tank and it seated. I also had to open the holes on the sender a little. The bolts on the tank were a little out of parallel, but it seated easily with a little opening of the holes.

So when I get a chance to add fuel I will report back.

[Dublinoh]

I am having trouble with a persistent very very slight leak at the return gas line that has a pressure fitting. My shop tells me it is a design flaw with the tank fitting. It seems like the male portion on the fuel line doesn't insert far enough into the fitting? Looks like either a creative way to hook it up or a warranty return. Let you know how it plays out.

[clesch]

Originally Posted by JP911

I bought a repro and had issues with fitting the sending unit. The studs on the tank did not line up with the holes on the sender. I had to open up one of the holes to get it to fit. No issues getting the filler neck to line up.

The studs for the sending unit are not symmetric although they look like they are.
I had the same issue as you (one hole didn’t line up) and simply turned the sender unit until all holes lined up...

[Dublinoh]

We are in the process of braising a new fitting for the return fuel (pressurized side) which would not seal. I'll let you know what happens..

[Dublinoh]

The tank is back in and working. The fitting that was originally installed was drilled way off center and would not seal. I had $200 invested in Line-x coating and decided to repair the new unit rather than return for warranty exchange. If you buy one of these check the fitting before any install or painting. It came with a plastic cap on the fitting and I didn't see the off center hole in the fitting until the last step of the install.

[JP911]

Originally Posted by clesch

The studs for the sending unit are not symmetric although they look like they are.
I had the same issue as you (one hole didn’t line up) and simply turned the sender unit until all holes lined up...

Didn't matter. I had the orientation correct, but the holes in the sender did not line up. I had to use a small rat-tail file to open up one of the holes.

[Dublinoh]

Originally Posted by JP911

Didn't matter. I had the orientation correct, but the holes in the sender did not line up. I had to use a small rat-tail file to open up one of the holes.

I also had that issue and needed to open up the holes, but easy fix.

[BoxsterGT]

Its been a while since these were available. Have there been any improvements to date, or are the new ones still the same?

Len

[BoxsterGT]

Anyone bought a repro tank recently? Does it fit as expected?

Len