I have the new extra fuel tank for the bed, sized 55" long x 16" high x 13 1/2" thick, holds 50.43 gallons of fuel. It has a 1 1/2" NPT filler hole. 1/2" NPT vent hose hole and a 1/2" NPT fuel line hole, made from 1/8" plate steel, 3 inside baffles, welded and pressure/leak tested etc.

There are several places where light rust is just starting, I plan on having this extra fuel tank coated with the bed liner material when the bed is done. Do I need to sand/remove the rust and primer coat the tank before spraying the bed liner on it, or does it matter? I also plan on having all the mounting bolt holes and holes for the hose lines drilled into their proper places before putting on the bed liner etc.

Will the bed liner material rust proof all the bolt and hose holes in the bed? Is there anything else I should do too the bed or tank before the coating is sprayed on? I plan on having the filler neck/vent lines on the bed tank also coated with bed liner material etc.

After the coating is done, there will be a 1/4' thick rubber liner on the bed floor, the bed tank will mounted on top of the liner and bolted down and the new caravan camper shell bolted on the bed making everything weather proof.

Does anyone know of a way to mount the caravan camper shell to the bed rails, WITHOUT drilling bolt holes into the bed rails etc?? The bed has the plastic coverings on the top of the bed rails, and I think they will have to be removed before the camper shell goes on.

Tia,
Don

 

For the tank, remove the rust with a DA sander and scuff it with a scotch brite pad. That should be all the prep you need. If the inside is also starting to rust, you may want to consider a fuel tank coating product. I know Eastwood makes one.

Bed liner shouldn't be sprayed on the bolts. You'll have a bad time trying to remove them later. Instead, I recommend you mount the talk with stainless steel hardware to avoid the rust. If you ever need to remove the tank you'll be glad you did.

I have seen camper shells (or toppers or canopies depending on where you live) held on with C-clamp type devices, but it isn't something I would try. Any time I have had one I bolted it to the bed.

The plastic bed rail covers will come off, but are usually damaged in the process.

 

They make aluminum clamps specifically for clamping canopys/toppers to pickup boxes. Depending on structure and weight, you can use 2 or 3 per side.

I've used these with a fiberglass canopy for years. No movement, even when off roading.

Good luck.