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Gas tank replacement

From 1986 Ford Bronco “Eddie Bauer” — documented by Sixlitre.

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1986 Ford Bronco - Old tank out and into the wheelbarrow 1986 Ford Bronco - The vent hose within the filler hose 1986 Ford Bronco - Ugly looking 86' in-tank fuel pump/sending unit. It's older than the old tank, which I stuck in new in 99'. Gotta save the unit and sacrifi… 1986 Ford Bronco - The vent valve popped out very easily (Thank goodness). So many people bust these things removing them. 1986 Ford Bronco - Got her out intact ! Whew ! 1986 Ford Bronco - Hope I can find a new filter screen ! 1986 Ford Bronco - When I finally got the plug off the sending unit I found one of the three socket terminal clips had busted off. Sure hope I can find a new… 1986 Ford Bronco - Only 8 years old and this tank is toast ! Gonna do some coating on the new tank so I'm not in the same position so soon again. 1986 Ford Bronco - The 86's have the in-tank pump "AND" the gauge sender unit on the same stalk and their plug/harness is NLA 1986 Ford Bronco - Couldn't find a new plug, so I drilled out the busted terminal and install another. 1986 Ford Bronco - For around a buck I got a whole package of these handy dandy little terminals. Not an exact fit, but with a little persuasion from a tapere… 1986 Ford Bronco - The ground wire now sticks out the back on this McGuyver'd plug 1986 Ford Bronco - I whittled the back of the plug out to semi-recess the wire into the plug a bit and make it easier to glue in solid. Being from Mopars I us… 1986 Ford Bronco - Because of the corrosion up here I even lubed the soldered joints with dielectric grease before I heat shrunk over them. After that I goope… 1986 Ford Bronco - A little automotive Goop keeps it in place and weatherproofs it nicely. 1986 Ford Bronco - Beautiful new Canadian made steel tank for $130.00 CDN. How do they do it ! Note the smaller 2" opening for the 86 style sender unit, as op… 1986 Ford Bronco - After cleaning the packing grease and residue off the tank with acetone, I emptied two of these spray cans of clear urethane onto the tank.… 1986 Ford Bronco - Beat the dents(left of tape measure) flat with a small sledge. Ground enough rust off the saddle points and sprayed with paint, so the foam… 1986 Ford Bronco - Steve83 suggested using camper top foam backed tape and I'd say he was right on the money. Works great and was fairly cheap at $15.00 CDN (… 1986 Ford Bronco - I even stuck an extra layer of the foam tape right onto the tank's saddle points for double protection from that rusty old skidplate. No it… 1986 Ford Bronco - There's my favourite anti-rust grease in action(painted the floor above the tank while it was out too). After seeing the rusted mess it was… 1986 Ford Bronco - The vent valve going back in. Be sure to install the rubber grommet first and then the valve. 1986 Ford Bronco - Note the orange O-ring on the R/H nipple. For better or for worse these 86 connectors use the same clips as later fuel filters, making them… 1986 Ford Bronco - There it all is, tank in the skidplate, ready for me to do my bench pressing impression. Note the spray can lid over the filler neck to sto… 1986 Ford Bronco - All done. Six coats of clear urethane for protection. Hooked up the lines, stuck in the filler neck with it's drain back vent and even clip…