A few of you may have noticed the pop rivets in the last photo, well the next bit is bad.

They have offered up the petrol tank, and found that the pump/sender unit is right where the U channel is on the boot floor.
So now the tank won’t fit because its in the way.

Solution, no problem, they decide to make a few adjustments, and slice up the floor and remove the offending U channel, then pop rivet it back together with some scraps of metal and plaster a load of goo over the top, “sorted”.




Now they are hanging a half sized petrol tank, plus a heavy 80Ltr gas tank from a weakened floor.
The thing is, as they would have encountered the same problems every time they installed on a Cherokee, I bet this fix was the norm.

Be afraid, be very afraid.

Good luck!

It will be interesting to watch a dual fuel being refurbished.

I've always wanted to go to Scotland. Looks like a beautiful country.

my family originated in Scotland, nice to know XJ's are appreciated there. I'll have to bring mine over and run around with you on some trails over there

Wow... A full tank would be about 126 lbs + the weight of the actual tank... Glad you are fixing it right... might have ended up as a fireball down the motorway!

Down a bit from Scotland, the Yorkshire Dales is mostly a National Park in the county of North Yorkshire

http://www.yorkshiredales.org.uk/

Its often called "God's Country" because of the landscape.

And the gas tank hangs off of it as well.

So called professionals cashing in I'm afraid, Joe public is unlikely to lift the carpet, let alone crawl about underneath.

If it had been involved in a shunt it would have just crumpled on that corner.

A lot of XJ's have been converted to LPG over here, I hope not many by these idiots.

The gas tank was just corroded from stone chips and where it has been rubbing, so a blast and then some treatment, and several coats of paint.

The petrol tank needed a new filter head (on top of the pump/sender) as the outlet was cracked and must have been leaking for some time.
The tank itself was badly corroded, to be honest, if I had more time and money I would have fabricated a new one, but needs must, so a repair was carried out.
A bad section was cut out and replaced, the whole thing blasted, and several coats of paint.

New mountings were fabricated for the boot floor, made up of 150mm square sheet 3mm thick, with an M14 bolt (with its head removed) fabricated to it, this was then seam welded in place from the top of the boot floor (can’t find the pictures).
All mountings have heavy duty rubber spacers/packers, also heavy duty strips between gas tank and petrol tank, and between the gas tank and the boot floor, so nothing is now metal to metal.
All now re-installed.





Plus a bit of primer overspray from doing the bodywork.

The gas tank filler is mounted close to the standard petrol filler, unfortunately this panel is extremely thin, and the process of filling the tank, has bent and dented the panel.
I have now bonded a 3mm thick plate of aluminium to the back of the panel on the inside to strengthen it, now it is nice a stiff should not flex anymore.




The pipework from this down to the tank had to be re-routed as the original installation was bad.

Back axle stripped, cleaned, new driveshaft bearings and seals fitted.

To eliminate the end float I modified the “C” clips so that they were thicker, that way they could be ground to fit, to try and eliminate driveshaft end float, which seems to have worked.

New brake wheel cylinders, and brake shoes fitted, drums blasted and painted, and new copper brake lines fitted.

New rear leaf setup plus a spacer which gives me the look I am after.

I didn’t change the brake flexi hose, as I am replacing all of the brake pipes with copper I have made a bracket to re-position the flexi lower.



Front sits high because the engine is still out.

Also manufactured my own BPE’s for the rear shocks.



I used the pin from an old shock absorber and welded two side plates, should work OK.

You will also notice I have painted the roof and back door.

I had to bond the back window back in, as it was basically hanging on by one edge with loads of silicone.­­­

off topic, but i have family from Llangollen, Wales The countryside over there is amazing!

Very nice, not far from the Snowdonia National Park, very similar landscape.