Did you leave enough room for some insulation around the tank to keep it from rubbing against each other? Even though it might be flat and smooth a little foam will go a long way to keep the tank rubbing against the skid plate. Don't want to wear any holes in the tank although if you have a plastic tank it might wear longer.
Are you going to cut an access hatch for the sending unit in the floor of the jeep? I would hate to muscle that plate in and out to work on the tank.
John, I have not cut a hole (yet) for the sender. Four months ago, I put in all new tank, float and sender apparatus. I know I can still have problems though. Regarding the buffer zone, our 5 has a small body lift that i took advantage of and raised the tank 5/8" from the top of the frame, this was important for two reasons, first the fill neck is no longer rubbing the frame (causing the cracks i think) and two gave me some much needed room between skid and tank. The old tank had lots of dings and bends from the skid hitting it. I would be concerned about any insulation holding moisture and causing a rust problem, even here in so cal, the main problem is creek crossing and muddy roads.
Nut and washers under L bracket:
Fill neck, short version:
Before you box it too much, you may also want to think how much crud is going to be collected inside it. Crud is the main contributor to rust and building a box that is impossible to clean out or is closed on the sides may trap that stuff up next to the skid, tank, and frame rails.
Just something to think about.........
Yesterday, when I pulled the skid, a bunch of gravel/rocks were in the skid, this could be a problem if they gather and rub on the tank. I could integrate some holes along the side to shed small particles and water but the bigger stuff I might have to live with and check it once in a while.
How many CJs have skids like mine?