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Randy Pflanzer
Technology Professionals Consortium
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   What's New?
  02/01/13 - Reformatted web page.


The winter time in the Midwest is NOT a time to go cruising.  I pretty much clean up the car and put the cover on it around November 1 until April 1.  This down time is a great time to make minor tweaks to the car to correct any construction defects or just change your mind on something. 

Fuel Tank

The fuel tank leaks fuel when it is full.  I suspect it is the fittings in the top of the tank that are leaking.  So the first job is to remove the fuel tank from the car and check those fittings.

Surprise!  When I removed the tank the fuel tank level sender was sticking up about 1/8" above the surface of the tank top.  Seems the tank flexed and managed to use the fuel sender as a lever to pull the nutserts right out of the plastic.  this is a picture of the nutserts once I pulled the sending unit.  The other fittings on the tank were not leaking so I didn't mess with them.

I suspect that this damage happened when I hit a railroad track crossing that was surprisingly bumpy when i was going too fast.  I remember hitting it and it was quite a jolt.  I'm guessing that had something to do with this.

I spent a little bit of time figuring out how to fix this.  I wasn't thrilled about buying a new tank and I don't have the time to build one out of aluminum, so fixing this one is the answer somehow.

I decided to build a mounting ring out of aluminum and nutplates and seal this to the top of the tank.  I first used my Dremel tool to cut recesses in the top of the tank where the ring will sit.  I had to be carefull to not cut through the top of the tank in order to lessen the chances of this leaking.

This the reinforcing ring and gasket that I made.  I riveted nutplates to the ring to attach the sending unit.  The holes are countersunk on the other side and will be used to mount the ring to the tank.  With this gooped up with sealer, it shouldn't leak.

Here is the ring mounted to the tank top.  The four flush screws go through the tank and are held on by washers and nuts inside the tank.  I then gooped over them with sealer.

The nutplates on the reinforcing ring are then used by the hold down screws to attach the fuel level sending unit to the tank top.  This is the best I can come up.  I'll drive this for another year to see of it holds up but I will not be surprised if I have to pull the tank next Winter.

Bump Stops and Rear End Vent

I was very surprised to find both of my rear-end bump stops broken off when I was under the car removing the fuel tank.  Again, I bet it was the hard hit on those railroad tracks that did them in.  These are the ones that come with the kit and they are made of rubber.  It was suggested at the time of construction to upgrade these but I chose not to.  Well, I guess that was a mistake.

I ordered a set of polyurethane bump stops with the exact same dimensions from Summit and bolted them in place.  It was an easy fix.

When replacing the bump stops, I also noticed that the vent for the rear end had broken off flush with the top of the housing.  I could see where the straight tubing fitting that came with the rear end had hit the frame rail above it.  After removing what was remaining of the old fitting, I installed an elbow fitting which provides much more clearance under the frame.  I then routed a hose up and over the frame and secured it with a clamp.

There are more changes.  They can be found on the next page.