44 gal tank install/ help

[RimoniManu]

So I posted this on trailvoy but have been out of the picture for a while and didn't know about the "changes"
What I'm doing is installing a 44 gal fuel tank from an old Suburban. It measures 33" wide x 26 3/4" long x 13" high. I'll be installing it where my spare tire was and I'll be getting rid of my stock fuel tank because of some "other" mods I'm working on. I'll show and tell later on those.
Here's my progress so far:

First I removed the spare tire "crossmembers"
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I still need to remove both of these spare tire "braces"
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I'm not sure about the short wheel base versions but my EXT has this "secret" compartment that I'll be cutting out and then welding a plate sheet in it's place. That way I can tuck my new fuel tank tight up inside my frame for some nice ground clearance.
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I'll need to find a way to tuck these rear ac lines out of the way. ( any suggestions on this is welcome)
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Here's my fuel tank I'll be putting in. I'm going to cut the filler neck and weld it facing the direction of the arrow. I'm also going to cut the lip at the seam and then weld the two halves together so the tank can fit better between the frame.
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While I was cutting I decided to flip my trailer hitch upside down. There is much more rear ground cleance. I cut off the steel step support for the bumper and had to cut out the center step of my plastic bumper.
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As you can see is this next pic the bolt holes don't line up. So all I did was pull my trailer hitch out to the next bolt hole to line up. For the time being I'll leave it like this because when I make my steel bumper I'll flip the brackets back so all 6 bolts line up.
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This has been a slow process because of the weather, I live in Seattle area. Any advice on the ac tubes is appreciated. Also, any advice for all the sensors and junk we have monted ontop of our tanks; as you can see my new tank only has a mount for sending unit, but we have about 4 or 5 other things I'll need to mount. I was just going to drill holes in my tank to mount them. Is that all I can do or can I just toss them? lol Thanks for lookin

[NC_IslandRunner]

What pics?

[Philberto]

[NC_IslandRunner]

[djthumper]

The image tags don't like the feed from imageshack.

[NC_IslandRunner]

Try photobucket, it works everywhere.

[djthumper]

Unless one of the other mods can get the tags to work. There is something the img tag dislikes

[RimoniManu]

sorry I've never used imageshack and wasn't sure which link to insert. got it working now.

[NC_IslandRunner]

Much better, Gonna cage the fuel tank?

[RimoniManu]

I'll have a skid plate on bottom. Not enough room for an entire cage. It will fit snug between the frame. If I remove that "secret" compartment then I can tuck the tank so the bottom is flush with my upside down tow hitch.

[fishsticks]

Mounting shouldn't be hard.

How are you going to handle delivery?

[RimoniManu]

That's something I'm asking advice on. I'm going to find a TB sending unit and pump and "try" to see if I can make it fit. I don't want to have to rewire anything. Once I drop my stock tank I will then measure hole sizes for evap and pressure sensor etc. and then make mounts for my new tank

[chevycrew]

Check fuel pressures, you may be able to use a pump from a 90's chevy truck, they dropped in a metal tank similar to the suburban.

Kinda cool not being the only one with a flipped hitch now!

You also may want to look into z71 springs, or some air bags to handle that extra 300+ lbs hanging out behind the rear axle.

[RimoniManu]

ya i already have z71 spring in rear and love em. I'll give it a shot. Thx

[fishsticks]

How about sealing the extra tank and gravity feeding to the original tank?

[bartonmd]

I REALLY hope you have a TIG welder that you are REALLY good with, if you are going to try and cut the seams off of the tank, and weld the halves together!

So... What are you doing with the middle of the vehicle, where your tank is, now?

Mike

[Trail X]

There's a body seam behind the hidden tub, is that not going to get in your way?

Fuel pump and level sending units might not communicate between a 90s truck and a 2000s truck. See if you can get your hands on one first, and do a trial run with some gas in your new tank, and the older pump. I think you'll have less headaches if you can find a way to use the pump for your vehicle though.

Is the metal tank lined inside? I would assume so. Keep in mind that your new welds will need to be lined after you reattach the halves. Or is the tank aluminum?

44 gallons... I'm amazed that you can fit that much back there, sweet!

[RimoniManu]

barton, if you told you now it wouldn't be a suprise lol. fishsticks, a while ago I wanted to have an aux. tank but now with my "other" ideas I need my stock tank gone and out of the way. James, you're correct there is a body seam where the rear cargo door latches to. I'm going to cut out a notch along the entire length of my tank so it can fit around that body seam like so:
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[bartonmd]

I'll tell you right now, if you're going to be welding the seams, and cutting a notch out of the corner, and likely doing something different with the fuel pump/sender mounting, you will be time, leaks, and headaches ahead to just TIG weld up your own fuel cell; or if you just have a MIG, get a custom fuel cell made to fit what you're doing...

Mike

[RimoniManu]

ya I thought of that too. But before I spend time and money on that I'll give this a try since I already have the tank. since no one has done it, right now it's a guessing game anyways.