Fuel Tank Reline - 73 Westy

[DurocShark]

Part 1

As discussed in my other threads, the tank in my 73 is rusty. Bad. It got to the point where I couldn't drive 3 blocks without fuel starvation. I found a local radiator shop that quoted me $80-120 for a cleaning and reline. The high end is if the tank requires welding.

Before I started:

First I drained the tank. Let me tell you that gasoline in the armpit is NOT a good thing. Had about 8 gallons in there, so I filled a 5 gallon jerry can through a coffee filter, and poured it into the Volvo. Then the rest went in the jerry can to return to the bus so I can get to the gas station.

Then I removed the air cleaner, balance tubes, and intake manifolds with the carbs still attached.

Only one nut on the left manifold was tight. I can't believe I missed that little detail!!! I'm surprised the thing ran at all!!! Sigh.

Also, what's the tube that bolts to both manifolds and runs through the firewall? It's not the brake booster tube... I haven't tried to trace it under the bus yet since it goes above the transmission. The Tee connector for the fuel lines to the carbs had rust in it. Grrr...

After stuffing the heads with paper towels I pulled the fan and charcoal canister. Everything looks clear to remove the tank, though I may pull the distributor if I need to.

Man the engine compartment is a mess!!! Filthy, lots of loose screws and washers and such. Even a couple of pennies!! How does someone get pennies in the engine compartment of a bus?!?!?!?!

Did the screws on the firewall. The two under the bus are WELL hidden. No wonder so many folks miss those. And you need a long phillips screwdriver to reach them, which I don't have at the moment. That was entertaining...

Firewall came right out no problem.

Rest of the pics. I'll go back out after getting something to eat.

As you can see, the fuel tank had rust even on the outside. Can't wait to see what kind of condition it's in...
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No boom today. Boom tomorrow. There's always a boom tomorrow.

[DurocShark]

Ok, it's out.

The straps are held to the floor by a bolt that's fastened to the strap (welded?) and a 13mm nut on the underside of the bus.

Ahhh, yes. Rust. Both nuts became perfect circles when I went to remove them. So I dremelled the straps. I have a few days to come up with a solution while the tank's in the shop.

Speaking of the tank, it took some fiddling to get it out, but not nearly as bad as I had expected. I had to drop the coil down and remove the distributor cap, in addition to the previously mentioned intake removal. Otherwise, not really a problem.

Tank had a small handful of rust in it. It's relatively clean on the inside! Better than the ones I've seen posted! No pics because I didn't want to take the time to dig up my lighting, etc. I'm smoking a last cigarette before heading over to the radiator shop.

I did notice the sock was completely missing. Possibly the tank's been relined before and the sock wasn't replaced? I feel that if the sock had been present I would have never noticed the rust.

The vent line rubber was good, as was the hose to the inlet. Another reason to suspect a previous repair.

Anyway, I'm off. I'll let ya'll know how it goes.
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No boom today. Boom tomorrow. There's always a boom tomorrow.

[ratwell]

[Duncwarw]

FWIW, I twisted one of the straps until it broke off. I was working alone and obviously I was underneath so I didn't know until it was too late.

No big deal. It gave me another excuse to use my beloved MIG welder.
I just fabricated a new bottom end of the strap and bolt assembly.

Lights? You mean syou used studio strobes and a REAL camera to take the pics you posted? I finally found one reason to own a digital camera when I did my tank resto.

I'll be interested to see how the tank looks when you get it back.

Keep 'em coming.
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“To find yourself, think for yourself”
Socrates, 470 BC - 399 BC

[DurocShark]

Dropped the tank off. Eastside Radiator and Welding.

Guy said the tank looks good, just surface rust. He's going to clean it and line it with epoxy anyway (at my insistance... I don't want to do this again anytime soon). Total cost $60-70.

I didn't think to ask about painting the outside. Oh, well. If he doesn't I'll do it when I get it back Friday.

Not bad overall, though I think my lack of a tight intake manifold was a bigger problem than the rust!
_________________
No boom today. Boom tomorrow. There's always a boom tomorrow.

[DurocShark]

Pics after pulling the tank:

And a closeup of the outlet tube. The rust appears to be built up there.

Notice the rust at the inlet opening? After the rain passes I'll inspect the inlet tube more closely. Maybe a leaky fuel cap started this whole mess?
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No boom today. Boom tomorrow. There's always a boom tomorrow.

[DeathBus]

Dude you got a good deal from that shop. Check out my gallery pics for a 412 tank me and a buddy welded and had treated at a radiator shop.

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65 Bus, 72 Bus, 63 bus, 98 Golf, 92 Cabrio, 71 Fasty
In the shop a 62 Bus and a 79 bus

[daves_ale]

HElluv a deal at the radiator shop. Can't even find someone local around here to even boil thhe things clean anymore.

All said and done I paid about the same for doing my tank myself and it took a week ( at least ) to do it in.
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"Beer is proof that God loves us and wishes us to be happy"- Ben

'66 Euro Beetle 1200A
'71 Single Cab
'78 Westy
'02 Jaguar XK8 convertible

[DurocShark]

I just got back from picking up my tank. Total cost to have it de-rustified and epoxy lined: $70.

The guy said there was VERY little rust inside. The pieces of rust didn't apepar to be steel rust anyway, he said. Too bright orange. Possibly the sock disintegrated? Or something got inside via the filler neck?

Anyway, no pics since it's raining/hailing here in Colorado and I refuse to expose it to moisture after getting it all fixed.
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No boom today. Boom tomorrow. There's always a boom tomorrow.

[VWGirl]

those straps can sometimes be a pain... but why are your tanks rusty on the outside??? even my tank that poured out several cups of rust from the inside wasnt rusty on the outside... had some dirt on it...but not really any rust