Hey all, I'm brand new to the forum. Frankly I'm at wits end. Purchased a 1992 XJ about a year ago and have had two fuel tank structural failures in a row. Both tanks were absolutely brand new. Essentially it appears that the fuel tank straps are compressing the tank, causing it to buckle in the middle and eventually fail. I'm attaching a couple pics. Has anybody else ever had this issue? I've searched high and low and haven't seen anyone else with this issue. Any advise would be deeply appreciated, the rest of the vehicle is perfect, just need to solve this. Any ideas on strengthening the tank or aftermarket straps that conform to the tank more effectively?

 

Metal straps should not make contact with the metal tank.
On the metal tanks there is a plastic cover that goes over it, then the straps go over the plastic cover. Tightened snug but not over-torqued where the strap starts distorting the tank.

 

Yep, plastic cover was in place on both occasions. Neither time were the straps torqued down. Sorry for not being more accurate in my initial description.

 

Strange, of all the XJ's I've owned I've never seen this issue.

 

I have never heard of this issue either.
In the picture, it looks like there was an object caught between the strap/plastic cover and the tank. Then object was pushed into tank when straps were tightened.
'Object' could be a deformation of the plastic cover? Time for a close inspection to look/feel for an anomaly.

 

Rear u joint break while driving? Throwing the driveline up and hitting it? Or is the tank too far back? just a thought...

 

I'm VERY skeptical of the tank strap causing buckling. I don't think you could make it buckle the tank if you tried.

Has this problem shown up in the same location each time?

 

Ya scratch this. I missed the part you're on the second tank..

Weird.. ?

 

Hey all, I really appreciate the replies. I've inspected the "skid" for imperfections and found none. As far as I can tell right now, the straps that hold the fuel tank to the frame simply make poor contact with the tank. Essentially the main points of contact between the bands and the tank (obviously through the skid) end up occurring largely on the sides of the tank due to the flexed contour of the bands. This is why I was asking if aftermarket straps were available that more effectively fit the tank. As best as I can tell, the tank ends up buckling due to the tank being squeezed and compromising structural integrity. If i can't find an easy solution to this I was just thinking about ordering a 32gal tank and calling it even. Tired of swapping tanks lol.

 

Yes, but that's ALL tanks on ALL vehicles I've ever looked at. But I've never heard of a problem like this.