as many people know, the stock placement of the XJ gas tank flat out sucks, it hangs a good 6" below the framerails. and if you're doing any kind of stretch it can get in the way of the diff.

well, in my case...I landed on it and crushed it in, resulting in a inability of me to fill it with gas.



So i decided to fix this

First off removing the old


measure the dimensions of the stock tank so you can transfer that to the floorboard to cut.... then, cut




cut a hole to run the new fill hoses. i decided to keep the same fill location.




then i ordered a 24' stick of 1x1x1/8" box, and some heavy gauge sheetmetal and got to work







i then cut the hole out for the filler hoses and welded the box to the floorboard. and then i started making the filler hose covers out of the same sheet metal and welded it all up.

everything is sealed up air tight. the top cover is removable to allow access to my shock tower and to the fuel pump and sealed with a kind of "dry caulk" that is reusable









painted it all up with the cheapo spray can liner


and showing where the filler neck ended up.


the interior is back in and the rear seat still fits perfect. ill have to get some pics of everything put back together

 

thanks for making a thread. I was just wondering on how to do this the other day
looks good and functional

 

loks sweet, i plan the same mod, but with a shelf above, OBA tanks on the side.

 

Are you at all concerned with the angle of that filler neck? I've read quite a few people having issues with the stock filler location. I relocated mine to the window area when I relocated my tank.

 

I still have a downward slope with the fill tube. And i did some pretty serious wheeling yesterday with a lot of off camber stuff with around 12gal without any fuel spilling. So I think it will be just fine

 

This is what I want to do since my tank has been taking a beating as well.
You say no fuel spillage at all? Do you have a stock fuel cap cause I've have a issue with spilling fuel in off camber positions even with a new gas cap.

 

yes, still stock cap. and i didnt see any signs of spillage after wheeling yesterday.

 

This was the best mod (besides lift) Ive done to my XJ, the added clearance is amazing!

 

Did you also seal the seams on the side sheet metal panels? I see they were just stitch welded. You definitely don't want any fumes able to seep into the cabin if the tank is somehow compromised.

 

After being refreshed of seeing this thread I just did it yesterday and yes there is a ton more clearance. After I dropped my tank and took the plastic guard off it was pretty clear I've dented it up pretty good lol just glad it had not hit where the pick up tube is.

 

Yes, I only stitched the panels to minimize warping. But EVERYTHING was seam sealed with high quality sealer. That box is air tight now.

 

Lol, I crushed in where the fill tube is. And it made adding gas just about impossible. Almost 10 minutes just to put in 3 gallons.

But when I had my tank out I clamped off the hoses and pressurized the tank with shop air. That did a pretty good job popping out all the dents

 

i think you and me spend too much time on pirate lol

 

i spend a little time there...lol

 

Cool mod. I need to get a welder and start messing around.