Doc's ZRV(Pic Heavy)

[Doc2012]

Here it is guys. Still need to do some more work, but for now, they fit.

I'm going to add some BBs to them tomorrow and then put them back on the truck. I deflated the front two tires, they popped right off the rim, and I haven't been able to get them back on. I don't have any starter fluid, or brake cleaner, so I'm kinda SOL.

I'm going to be adding 10oz of BBs, maybe 12. Maybe 15. There's no harm in adding more, but not having enough is not going to balance the tires.

Basicaly, what I did was took some 3/4" electrical tape, lined it around the fender, and then cut.

Here's what I got.





Did the same process front and back. Here's what I cut off:

And here's what she look like with them on:

As for the firewall, I just beat the hell ot of it with a BFH for now. I'll do some more cutting and welding when I have a better work area.

I still need to add some metal to the rear wheel wells, to keep that area clean looking, and to keep the metal from separating. Peobably gonna do that tomorrow.

More Pics to come.

 

[Singtoe]

Your going to need a step ladder to get in it now...

 

[Doc2012]

Your going to need a step ladder to get in it now...

I do have to hop......

 

[HOJeepster]

that is a beast. 37 is a big ole boy

 

[Doc2012]

Ok. First, a little trail damage from Uhwarrie Saturday.

Got it fixed for the most part tonight. Just need to add some metal to beef it up and I'm all set.

Second, there's something that's been weighing heavy on my heart every time I walk into the garage.

My gas tank.

I know. I know. You have all been waiting a LONG, LONG time.

Go two pages back. The basic drawing of the side view of the gas tank is there. It was going to be 45 Gal.

I was excited about this, because it meant I could go on LONGER wheeling trips, without having to fill up or carry extra cans around.

Well, in my naivete, I didn't think about the cost. I figured, "sure. It'll be more expensive, but WTH. It'll be work it."

Wrong way to think about it.

That, and I didn't really think about the flex of Riley.

So, I decided to change the gas tank up a little bit.

[MENTION=55891]Bandit Runner[/MENTION]; if you could please mod this into CAD real quick and tell me what the total gallons are, I would greatly appreciate it. My math isn't what it use to be, and I can't seem to remember the formula, nor how to even describe it, to figure out the part of the tank that I'm going to show.

So, here was the old tank.

And here's what I've come up with now.

So my dumbass hit the reply button instead of the preview button......

The reason for redoing the tank is because of the flex. I want to be able to flex fully and not hit the tank on any rocks or anything. I still plan on running a 3/16 or 1/4" skid though.

Expect some mock up with foam board/cardboard this weekend.

 

[Singtoe]

Don't forget the FJ meet this Saturday in Raleigh. You and Rudy have to come.

I will help tig up the gas tank.

 

[white_n_slow]

I'm curious, since you chopped your quarter panels, do you think it would be possible to just run a bead of weld between the two pieces of sheet metal to join them together without adding the wire like they did in the TLT article?

 

[Doc2012]

Don't forget the FJ meet this Saturday in Raleigh. You and Rudy have to come.

I will help tig up the gas tank.

I can't man. I don't have the funds to get back and forth from J-vegas to Raleigh.

Rudy is going home, as in to Maryland.:whip:

I'm curious, since you chopped your quarter panels, do you think it would be possible to just run a bead of weld between the two pieces of sheet metal to join them together without adding the wire like they did in the TLT article?

You could, but i think the edges would still be sharp. Not to mention, IDT it would look as good.

 

[Doc2012]

UPDATE!!!

Work continues on the gas tank. Here's the foam board cutout. One Big *****....

Held in place by twine:

Flexed out:

I think I'm going to stick to what my plan was before. Take 6" off the sides, and 4" from the total length, possibly 2" from the top, and maybe 1/2" from each side, so that it's 35" instead of 36" wide. Idk about the top part yet. Seems like the axle will keep the tank pretty protected....

Whatcha think so far? As I said, work continues.

 

[Doc2012]

OK. Here ya go guys. Some more progress.

Got some done, but more to follow tomorrow. Went to look at a puppy tonight, and now watching Chael Sonnen PROBABLY get his ass kicked....

What happened to him? He had Anderson Silva done for! Now, he just bullshits...

Oh well. Back on topic.

Here are the lines that I came up with before going to look at the Puppy.

Heres the cuts. I also took 4" off the back, but didn't take pics of that.

And here's the finished product.

Don't think I lost too much. Maybe 5-6 gallons, maybe more. But hey.... Still better than that Crappy stock 18 Gal.

The dimensions are roughly the same:

36" wide, 15" at the deepest part, 9" on the sides, and 9 inches in the back, 20" long.

I'm still debating on taking an inch off the width. We'll have to see what it looks like when I go to put it back in tomorrow morning.

More progress to come tomorrow.

 

[TCMach]

I missed your original post about the tank so forgive me if you answered this already. First, what are you going to do about the sending unit? Will it end up working with the stock gauge or are you going to run something else? Second, are you going to add any baffling to the tank?

I'm anxious to see how it turns out because I've been debating the F150 tank swap but it's really not an upgrade (capacity wise). A bigger tank would be much better in the long run.

 

[Doc2012]

I missed your original post about the tank so forgive me if you answered this already. First, what are you going to do about the sending unit? Will it end up working with the stock gauge or are you going to run something else? Second, are you going to add any baffling to the tank?

I'm anxious to see how it turns out because I've been debating the F150 tank swap but it's really not an upgrade (capacity wise). A bigger tank would be much better in the long run.

When I did my lift, my drive shaft broke. It took out my pinion on my rear diff, my gas tank, and my muffler.

I got the tank from Singtoe, and put it back in. I cut all the mounting stuff for the OEM pump, sender, and evap lines off of the old tank.

My plan right now is to run all the OEM stuff, extend the wires from the stock fuel pump location, and move them back to the new tank. The Evap lines will be the same concept.

I thought about the F150 swap, but there were a couple problems.

1) Same Capacity as the stock tank.

2) The Ford sender works on a different Ohm than the Toyota sender. It would read backwards, and wouldn't read past a quarter tank.

3) The level has to be modified in order to read the tank right.

I wanted something that was going to use the OEM stuff, NOT take up space in the back of the rig, but be able to extend my range. The tank was orginally going to be 45 gallons, but that's a little hard to keep full.

Not to mention, the ammount of flex I have, as you can see in the pics, kinda hindered the flex from the suspension......

 

[TCMach]

Yea those are the exact reasons I don't want to go f150. I've seen people cut out the stock sender and weld in a plate that fits the Toyota one but If your putting that much work in why not just make your own. The other option I've seen was an auto meter ford specific fuel gauge. But that's another bit of cash that could be put towards making my own and just having it be plug and play.

 

[Doc2012]

So I was a little off on my capacity, but it still holds 34 gal. I filled up 3 5 gal jugs twice, so six jugs total, then added 4 individual gal.

Here's the foam board cut out in the truck.

Here are the lines on the old tank.

And here's the tank all welded up.

Got a little more work to do. Need to clean the welds, add the OEM stuff, paint and coat it, and she'll be good to go.

 

[downpour11]

Damn that was quick! Nice job Doc :thumb3:

Now you'll have to post in one of the hundred "how many miles do you get out of a tank of gas" threads... and just not mention how big your gas tank is LOL

 

[Singtoe]

Should have tig ed it. I think your going a bunch of microscopic holes. Did you weld the inside joints?

Test it with some water and see how it holds up.

 

[Doc2012]

Damn that was quick! Nice job Doc :thumb3:

Now you'll have to post in one of the hundred "how many miles do you get out of a tank of gas" threads... and just not mention how big your gas tank is LOL

Thanks man. I can get shit done when I put my mind to it. Lol

Should have tig ed it. I think your going a bunch of microscopic holes. Did you weld the inside joints?

Test it with some water and see how it holds up.

If I had a TIG welder I would have. I would love to have one, or have come up there to have you do it, but it's just not in the budget.

I had a couple small holes, not a lot, surprisingly. I got them taken care of though. Ground down all the welds to make it smooth, and re welded the holes.

I did also weld the inside. Gonna grind them down as well and do them again.

 

[Dous]

Are you not worried about it going "crunch" on the rocks? Looks like it may hang down sorta low in the rear

 

[Doc2012]

Are you not worried about it going "crunch" on the rocks? Looks like it may hang down sorta low in the rear

The tank SHOULD be covered by the axle and the tires. They should give enough protection that any rocks will either hit them, or the tires will give the clearance to get the tank over them.

BUT, I have thought of that. I'm going to call Bud tomorrow and see how much he wants for a custom 3/16" skid. If it's going to be too much, then I might just get some myself and make one.

Either way, there will be a skid plate protecting the tank.

 

[zooroadbaja]

are you going to run any baffles or get a custom bladder made?