Restoration diary / 13-03-2005

13-03-2005 >> New top for the fuel tank, (pre) welded everything together, including filler arm.

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13-03-2005 - Made a new top for the fuel tank (with the help of Mark) to replace the previous one. Added two grooves for strength.
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13-03-2005 - Close-up of the groove.
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13-03-2005 - Test material. First tried a big groove, but this was too much, it affected the form of the sheet metal a lot. Next to the big groove a test run of the smaller version.
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13-03-2005 - Test run on a bended piece of sheet metal. Made a tiny error while making the groove, that's why the test piece is curved.
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13-03-2005 - Another way to strengthen the top. This works better, this test piece is very strong, but the non-bended sides curved up. This would make welding harder.
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13-03-2005 - New top tag-welded with the MIG welder. Final welding will be done with a TIG welder.
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13-03-2005 - Another view. Everything fits nicely. Visible on the left is where I added spot welds to weld the side to the inner structure.
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13-03-2005 - First time the fuel tank hangs under the Van. Mounts are tag-welded in place.
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13-03-2005 - Mounts fully welded in place. One on the left side, one on the right side and two on the front.
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13-03-2005 - All mounts fully welded, I keep changing my MIG welder from stainless to normal steel and back...
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13-03-2005 - Left side mount.
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13-03-2005 - Cut the tank filler to the right size, welded it in place and added the 'mouth'. This took the whole Sunday, I think I've mounted/unmounted the tank about 20 times in a row to get everything to fit. And I think I succeeded! :-)
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13-03-2005 - Close-up of the tank filler mouth. The end is normal steel, I'm not sure how I'll protect it from rust. It used to be protected by solder.
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13-03-2005 - Close-up of the filler-to-tank welding. The top of the filler lines up nicely with the top of the tank.
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13-03-2005 - Tank and filler in place as seen from under the car, looking rearwards.
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13-03-2005 - Filler coming the the floor. Both holes will be filled with a rubber ring.
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13-03-2005 - Filler mouth.
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13-03-2005 - This is the biggest accomplishment of the day, the filler is less than 1 mm out of place. The rubber that will fill the gap will push it towards the middle for a perfect fit.
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13-03-2005 - I can't get enough, here's another photo.
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13-03-2005 - And an overview from the underside with the exhaust back in place.
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13-03-2005 - Mind the space between the tank and the exhaust. Not too much, not too little. Also, the exhaust is a bit lower than the tank. In fact the tank is a (tiny) bit higher from the ground than the car's floor.