welding and petrol tank

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i need a lot of welding done on my offside chassi rail and the killer blow is that i have to remove the petrol tank, and it looks like the bolts to the bashguard and the tank are knackered. i reckon if they use sunk nuts rather than normal nuts and bolts it will be a nightmare getting it off (as i cant use heat or an angle grinder) and then they will have to be tapped to get them back on!

i also think the tank looks dodgy round the seal, can any tell me how much a petrol tank is or even a reconditioned one as i reckon 2nd hand ones will be just as bad.

sorry! its a Sportrak 1.6

sorry! its a Sportrak 1.6 ELXi 1995 M plate. Hardtop.


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i hope this helps

Hi there,
I'v just had my tank of my Fourtrack. All the bolts were rusted tight. To get most of them out I used the old trick of using a bloody big spanner and twisting the buggers off. All snapped cleanly off and it was a simple job to drill out and re-tap holes.
If you don't want to snap off the bolts then drill them out. Remember, there is a easy way and many hard ways to doing a job. So look at what you have to do and make a tool for it. i.e. if you are drilling up from under the car set up some type of leaver to help push the drill. I used an old bit of wood about 3 feet in length with my wife on the end. I was using the drill.
O' one other thing, make sure you support the tank before you take the last bolt out.(If your tank is as heavy as the Fourtrak's tank its painfull when it lands on your head....I'v got a lump the size of a golf ball!)
I hope this helps.
Greeny.

i got the bashguard off

i got the bashguard off courtesy of a drill and some hard work, the 5 bolts which hold the petrol tank on are now revealed and are so rusted as soon as i put the spanner on they just get rounded off so drilling is the call of the day.

hopefully once i get the tank and pump off i could get a grinder in and grind off the welded-on nuts. they i can renew them and/or tap the holes and install new nuts and bolts.

seemingly all the underside is rusted up, someone has done a bodge job on the fuel pump and its held on with cable ties, also the original metal fuel pipe has rusted off a long time ago and a previous owner has replaced the rusted section with rubber piping.

will have to fabricate a new bracket and get the pump bolted to the chassis.


PM me if you need Sportrak Help..