Searched for the mod to increase the tank capacity.
Found the full story with pics for the 97+ steel tanks.

Anyone have a link or modded an early 90's plastic tank?

 

Bahahaha! I don't know about your fuel tank, but I read your signature and couldn't help laughing my *** off!

 

43 lookie-lous and nothing?



Or are there too many 0bama supporters out there?

 

is this what you foundhttp://www.4x4wire.com/jeep/tech/fuel/nwmp04/

 

also found thishttp://www.go.jeep-xj.info/HowtoFuelTank.htm

 

 

For Pete's sake!

The early tanks are steel!!! Just a plastic cover to reflect obstacles.

All is good now I used 1/2 copper fittings glues together with JB Weld.

Gonna leave it set for a day.

 

Post a link to the modification please!!!!

 

I called NWMP and AeroTank and neither has a kit for 96+ XJ's. Any idea who might sell something for my '98?

 

Here's the link.
I used the 1/2" copper pipe method.
Took a few hours to accomplish. I replaced the 125K mile fuel pump while it was out w/new. Also bent the gauge float so it swings unrestricted.
Be sure to clean and lube the tank cover seal if your kit does not include a replacement. Its now nice to travel beyond 235 miles.

http://www.go.jeep-xj.info/HowtoFuelTank.htm

Fuel was added from completely empty. I added 25 gallons!
A slight smell of vapors is noticed when full and parked in the hot sun.

That odor disappears after the full tank drops off a few gallons.