DIY Fuel Tank Change

[paulf968]

Here are some pictures of the fuel tank in my 968.

I had to change it because of an ineffective 'swell pot' that caused fuel starvation leading to fuel pump failure -- this happened on trackdays, not in normal road driving.

 

[paulf968]

picture 2, top of tank cut off using a DIY jig-saw, showing the orange nylon swell pot in the bottom.

 

[paulf968]

picture 3, top of swell pot has a large hole for the fuel sender which is not in the shot. The lid of the pot is held with 3 clips and these fail to secure it properly and it is prone to lifting off, then the car exhibits fuel surge when cornered fast.

 

[paulf968]

picture 4, top view of the swell pot showing the 3 clip fixing positions, the entry ways that the fuel gets into the pot, the ally bit at the bottom is the outlet hole on to the fuel pump.

 

[paulf968]

picture 5, close up of the clip that secures the lid of the swell pot to its body, this clip hardens with age and loses its shape a bit. As a consequence it is likely that the lid will lift off.

 

[John H]

Facinating, and thanks for that Paul.
What is the tank itself made of?
Did you cut it? If so, with what?

John H

 

[paulf968]

John

The tank is made of a black nylon type material and has a wall thickness of at least 5mm -- the sort of nylon that some black dustbins are made of.

I cut it using an ordinary DIY jig-saw tool, just drilled a starter hole and away I went -- only took 5 minutes to go all the way around. No chance of re-using this tank now!


paul f