Well that sucks. I did a three inch single system on mine, with an offset/offset muffler. The tailpipe is about an inch away from the tank, so I may change the muffler to a center/center. The current muffler is too quiet anyway. :)

Original post edited to add pictures and explanation of ground wire for the fuel level sensor.

Mine is 3 inch true-dual with series 10 flowmasters(nice and loud). It is a custom made exhaust that was on the truck when I got it. It ends right behind each rear tire(you can see it in my sig photo). But when it goes over the axle, it comes back down right under each front corner of the rear tank, so it doesn't leave any room for a bigger tank, or even my full size spare :-X15

Gotta say, I like how they did the tailpipe exits. Seems like all of the less expensive exhaust kits exit under the rear bumper.

Maybe the pipes could be tweaked a bit?

I think they are about 12 inch tips welded on the exits. Probably one of my favorite things about my truck is the exhaust, I have never heard anything else like it.

When I bought the truck the PO said he got it done from stock for about $400. That included cats, mufflers, and the dual pipes. I was surprised, I thought for sure a setup like this would be a bit more $$$

I could try to see if the brackets holding up the exhaust could be adjusted lower without actually cutting pipes. I'll get under there again tomorrow and see If there is enough room to work with before I rule out this tank for sure.

Nice write up. I have done this upgrade on my truck and sure is nice for traveling.

Thanks! And I agree, this will be great for road trips.

Awesome, I was just coming on here to search about being able to use the high capacity tank on the '93 flare side I just picked up this weekend.

Excellent write up, thanks!

I'm glad you replied, I forgot to update this. I found an additional issue with extending the lines, and a quick fix.

I didn't realize that the hanger tubes have a bracket that screws to the fuel pump module, to prevent it from sliding off the tubes. I found out the hard way, my fpm slipped off the tubes, causing a no start/very low fuel pressure issue.

I made a bracket (really just a piece of stainless sheetmetal) that bolts to the original hanger tube bracket, and screws to the plastic fpm.

No problems since, and the Walbro pump is doing just fine.

Nice! I really need a bigger tank in my truck I'm always filling it every few days with all the traveling i have been doing for work and this would make it so much nicer! not to mention that my gad gauge is wrong. do you have to modify the fuel pump or is there one that can be purchased for the 38 gallon tank?I think mine is on its way out anyway so i would rather just replace it.

Thanks for sharing the pics for this project Bob Gervais!

You don't need this unless your uppper straps are rusted out, right? The 38 gallon upper straps aren't any different than the existing straps (used for the 18 gal rear tank)?

These are only needed since you're re-using your existing pump, hanger, and sender unit, right?

If my pump and sending unit is dead, I should probably just get a Bronco hanger. It looks like Motorcraft PFB4 includes the pump and hanger. The sender is Motorcraft PS22.

EDIT-
The Motorcraft part numbers I referenced above is NOT for the 38 gallon tank. They are for the 33 gallon Bronco tank (Spectra F8D).

Correct on the upper tank straps. Mine were a little rusty, and I had the bed off so I figured why not.

The bronco hanger may or may not work in this application. I think the Bronco tank is deeper than this 38 gallon tank. I had a used Bronco hanger to work with, but it didn't appear as though I could cut the required amount out of it to be able to use it.

The only modifications are as shown with the tubing on the hanger. The fuel pump is encased in the white plastic can, which I had called the fuel pump module. I'm sure there's a name for it, but that's what I called it. :D

As far as I know, there's no "drop in" replacement pump/hanger assembly that exists for using a 38 gallon tank in our body style.

You're right. My bad. I thought that the 38 gallon tank was the Bronco tank. It is not. It's an "optional" tank for the 85/86 F-series.

I wonder if the 33 gallon Bronco tank (Spectra F8D) will fit in our generation of trucks? That would enable us a drop-in hanger, pump, sender assembly.

Great Write Up Bob. With dual tanks changing the rear tank to a 38 gallon would give me 57 gallons total. At 17-19 mpg on the road that is a 1000 miles non stop for gas. Have to put a pisser in the cab I guess.
Thanks again Bob great write up.

Craig