One of the mods I was all too excited for, was getting my gas tank tucked. I have smashed it several times on multiple trails & it was time for a change!
On Oct 9, a couple of good friends (SkullysXJ & Volcom02WJ) and me cleared a Saturday to do some modifying. SkullysXJ (Kade) had already tank tucked a couple of weeks prior & so it was Cole's (Volcom02WJ) and my turn to do ours.
This is the last time it looked stock..
I started out by drilling a pilot hole in the spare tire tub to fit the shears in to
Cut out holes for the air return & fill tube
I cut the left side of the tank support from the frame and notched a location to clear the new fill tube & air return. I also cut out the flared portion of the tank (seen on the left & right side of the support) to clear the frame once tucked.
Unfortunately, my phone died & pics ran out. So here is what I had left. I lifted the tank up into it's new location, checked clearances, then drilled 4 pilot holes through the support and Jeep frame. Then lowered the tank & drilled larger holes to add Nutserts. After the nutserts were added, I lifted the tank back up & put in the bolts & sprayed everything w/ rubberized under coating.
Once the left side was done, the right side was easy. Did pretty much the same thing to it as the left side, except for notching for the fill tube (of course). This pic shows the holes made for the nutserts (right side)
Then after all of that, I cut the spare tire tub to size, put some relief cuts around the perimeter & flared the lip out, all to be placed back into the former spare tire location. I don't have pics yet, but I will get some.
Here is what she looks like tank tucked
And in action this past weekend in American Fork Canyon/ Mineral Basin Trail
For you dub owners looking for a good run down on how to do a tank tuck, refer to skullys 99 WJ build, Thunderball