38 gallon rear tank swap
 

Well, it is time for me to do something with the truck.

The 38 gallon F26C Spectra tank and a new 19 gallon sending unit arrived today. Only a couple small dents in the tank from shipping. Not too worried about that. What does worry me is the instructions that came with it. They included copper tubing to extend the pickup, but you have to solder them on. Soldering is not a problem, but if you follow these directions, the fuel level will read full until the tank gets down to about 1/2. Then it will start to move. They have you move the level sender farther into the tank.

Would I be better off getting the bronco fuel level sender for this or abandoning the instructions and extending the float wire by the same amount as the fuel pickup extension? Maybe some coat hanger wire soldered to the original sending unit wire?

Also, they include longer bolts and spacers for the stock 19 gallon tank straps. I no like this idea. Thinking of picking up some strap and making new longer straps. Anyone know what gage material the straps are made of? Looks like 3/16" thick? Are there aftermarket straps for the 38 gallon tank?

I am already committed to the project as the side tank already has a hole and unuseable, and the rear tank is now wet with fuel after filling it. Must be a small hole on the top. Why did I fill it? Cause this is still my primary daily driver. Lucky my commute is 8.2 miles each way.

Anyway, I had already decided to RedKote the tank prior to install. For this I dumped about 2 ounces of acetone in the tank and sloshed it around to get the thin film of oil off it. Then I realized "How do I get it out?". Grrr. Well, since I also needed a place to drain out the excess RedKote, I decided to solder a drain plug onto the tank. Drilled a 1/2" hole in the TOP right corner near the fill port and drained the acetone. Then stole the wife's hair dryer and on air only, no heat, blew air through the tank until the acetone smell went away. Then soldered a 3/8" brass drain plug and boss in place. Let it cool and acetone bath again. Immediately poured in 2 quarts of Redkote and sloshed it around. and around. Did it several times to make sure all of the inside was coated. Pulled the drain plug and drained the excess RedKote. Or should I say it is still draining next to me.

Why did I not change out the side tank first? Not sure but I wanted the big tank once I heard about it. Maybe I should wait on the rear tank and order the side tank, get it installed, and then do the rear tank...

Now I am rambling. Sorry.

Any ideas on my questions above? And what is a good tank exterior coating? I was just going to spray it with cold galvanizing compound and then undercoat it. Also, can you still get a new rollover/vent valve for the tank?

Weren't you worried about an explosion when you drilled the tank with acetone in it?

I'm thinking about the 38G tank too. Can you tell me how much deeper it is than the stock tank? I'm wondering about ground clearance.

It hangs down a little less than the stock tank with the spare tire there. You can't have the stock spare there anymore with the 38 gallon tank.

I will get pics later.

Fire? Explosion? No. Blew it out with air long enough not to smell the acetone anymore. New tank that never had gas in it.

I am thinking I should get the side tank replaced first, and then tackle this project...

And for anyone interested in Redkote, it is a tank sealer. Prevents the fuel or any entrapped water from ever reaching the metal of the tank. I poured two quarts of RedKote in the 38 gallon tank and drained one out. Looks like what I have left will coat the new 19 gallon side tank. Barely...

I bought fuel line and cut my sending unit. I then stuffed the copper extension they sent into the fuel line and reattached the sending unit on both ends. Soldered the wire extension in place and called it done.

Never used it, cause I bought my new work truck and have given it to my dad as a parts truck for his 83 flareside.

<a href="http://www.flickr.com/photos/cajun_croc/8135931905/" title="IMAG0168 by cajun croc, on Flickr"><img src="http://farm9.staticflickr.com/8045/8135931905_0d7be7e5f1_z.jpg" width="640" height="361" alt="IMAG0168"></a>

Kyle, that is exactly what I was talking about as far as the tank reading full until it was actually 1/2 or so. I was thinking of extending the pickup below the sender and extending the float arm to compensate and show true level.

My line of thought by extending it all as they recommend, was that it will read full for a long time and then the needle would start to drop.

I rebuilt the copper extension piece after soldering burnt it up. I played with measurements a little more and gave it some extra curvature, the pickup sits in the center of the 38gal tank I installed. I thought about fabbing straps, but after test fitting the install they are sturdy. I almost like it after seeing the fitment.

http://i202.photobucket.com/albums/a...o/HPIM2185.jpg

http://i202.photobucket.com/albums/a...o/HPIM2120.jpg

Subscribing because I like the idea with a thirsty 460 and a heavy foot. :D

It's good to hear what others say and see how they've dealt with the sender issue.

Thanks for the pic's Bryan & Kyle!

Here's what I had to do.
https://www.ford-trucks.com/forums/1...l#post13014676

I also thought about making new straps, but decided to test it without doing that and haven't seen a reason to do it after 5 months.

I just responded to your thread, Tom, before I checked this one.

The RedKote is about dry so time to coat the outside of the tank. Thinking cold galvanizing compound and then undercoating. That or POR15....

And I will be making new straps.