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Shavarsh
Shavarsh Reader
4/1/21 10:31 a.m.

After a lot more welding I rolled it outside with the new rear suspension for the first time. 

HundredDollarCar
HundredDollarCar New Reader
4/1/21 1:16 p.m.

That looks wicked.

This  is FANTASTIC 

BA5
BA5 GRM+ Memberand Reader
4/1/21 2:39 p.m.

Nice!  Looks like everyone is getting their chassis rolling!

Shavarsh
Shavarsh Reader
4/15/21 2:58 p.m.

Next up the mounts for the rear seat belts. my strategy was to weld 7/16-20 weld nuts to some large washers then weld that assembly to the bottom of a .120" plate welded to the frame.

 

Next up is gas tank placement. I ran into a bit of "measure once cut once" mentality here and I am not quite sure if this will all work as I want it to. Mockup:

 

Yes the tank is very close to the ground. However it has always been very close to the ground and its actually higher than the lowest part of the frame. Next some tabs for the mounting straps:

They are in funky positions and don't match because they need to clear the sway bar. These may come off and get repositioned.

Finally the first attempt at the trunk floor:

I may end up rebending this as well. I left some extra clearance on the gas tank/spare distance that isn't needed and eats up valuable real estate.

 

Shavarsh
Shavarsh Reader
4/27/21 10:57 a.m.

Does anyone run a bladder fuel cell on the street? I have been thinking about crash safety (it is a pinto after all). The tank is really squeezed in between the rear subframe and the back of the frame. The only place to gain more clearance is to notch the rear of the frame and move the gas tank up against the rear bumper. There isn't really anywhere else to put the gas tank though. I need to just mount the tank where it is and move on I think. Thoughts?

TurnerX19
TurnerX19 UltraDork
4/27/21 2:53 p.m.

In reply to Shavarsh :

The bladders all have a very short life span before  they seep, and the foam which makes them safer in a crash breaks down within 3 years with current street fuels. Metal tanks take much longer to fail without trauma, and are cheap to make. Put big bright brake lamps on it and it will be safer with metal.

Shavarsh
Shavarsh Reader
4/27/21 9:56 p.m.

I assume the molded plastic liners don't have the seeping issue? I am not too concerned with a bit of maintenance every couple years. Alternatively I may narrow the stock tank (front to back) to gain some clearance/crush space (~1"). Other benefits of the stock tank are the spare tire relief, and the fill neck in the stock fender location. Other ideas to increase safety?

78CobraII
78CobraII New Reader
4/28/21 12:50 a.m.

My understanding is that there were two problems with the Pinto gas tank fires. 1. The general lack of crush space in the rear, which was somewhat relieved by the gas tank being outside of the trunk (unlike earlier Fords) and being suspended by flexible straps. And 2. The sharp edges on the standard 6.75 inch differential which cut the tank open when it was shoved against the diff which was partially alleviated by the thick plastic shield retrofitted to the front of the tank.

If not for the sharp edges on the diff (and some E36 M3y Ford execs), the Pinto fires wouldn't have been any worse than early Mustangs and Camaros and all of the small Imports and even the midsized early 80's Malibu.

So I would put the plastic shield on the tank, make sure the tank straps are in right, and that the fill hose is outside the passenger compartment.  I think you have already added more rear structure to the rear than stock, so it should take an impact with less damage.

 

Shavarsh
Shavarsh Reader
4/29/21 12:42 p.m.

Any other thoughts? I am leaning toward cutting a section out of the tank to make room for plastic sheets front and rear. The issues with the fuel cell other than maintenance/cost/rework are the available vertical space (fuel cell must have a firewall between it and the passenger per nhra therefore I would need to raise the trunk floor significantly), the loss of the spare tire (I can live with that), and filling from inside the trunk (have to move things to get to the gas cap during trips and introduce the possibility of spilling gas in the passenger compartment).

 

If I section the tank and reweld I will plan to tig or gas weld the seam to prevent introduction of a brittle mig bead (likely to crack on impact). I will also need to extend the filler neck (making sure its at least 4" inside the tank) and find a new grommet for the tank. 

 

Any other considerations I am failing to see? Thanks Turner and Cobra for your inputs.

SkinnyG (Forum Supporter)
SkinnyG (Forum Supporter) UberDork
4/29/21 6:30 p.m.

Part of the recall kit on Pintos was a different (longer) filler neck that could flex more as fuel tank position got rearranged.

Filler in the truck is a PITA on trips.  Just saying.  Also doesn't really keep gas fumes out of the passenger compartment.  I'm sure you could make something work to get the outisde filler to fill a fuel cell.

78CobraII
78CobraII New Reader
4/29/21 11:16 p.m.

I agree on not putting the fill in the cabin. It will stink even if it doesn't leak.

You might try a plastic tank out of something like a Ranger pickup, but mount it sideways instead of lengthwise. I have no idea about fitment, but could get you measurements from the '99 in my driveway.  I don't recall if the fill is on top or in the side, but the fuel pump is definately accessed from the top after tilting the bed up. Been there, done that.

I've seen folks build heavy gauge steel cans around plastic tanks too.

I don't know what to tell you about the spare...maybe get run flats?

SkinnyG (Forum Supporter)
SkinnyG (Forum Supporter) UberDork
4/29/21 11:19 p.m.

I haven't carried a spare in any of my vehicles since 2001. Because (I'm stupid) reasons.

Shavarsh
Shavarsh Reader
4/30/21 11:53 a.m.

I am not too worried about the spare. I haven't carried one in this car yet (but I would like to add it if there is space). As far as the cell vs tank, I would rather use the stock tank unless there is a compelling safety reason to use a cell. Will a side fed cell with a rubber hose to connect to the filler, or a plastic tank actually be safer than the stock tank with plastic shields and the longer filler neck? (My car came with the longer filler neck and the plastic shield)

 

Thanks for all the input, I'll need to keep pondering this a bit

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