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-- STREET DRIVEN -- 1G FWD fuel tank options --

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bling5tatus

20+ Year Contributor
1,603
121
Sep 23, 2005
DFW/Austin, Texas
I have already read this thread:

I have already searched for aftermarket options using my internet machine. The options I can find are all fuel cells and this is NOT a race car. Why am I saying that? I am saying that because if it's a solution that takes up my limited hatch space, or space inside the driver's compartment, it will not work for my use case. This has left me with no options that I am able to find except figure out a way to make the tank I have still "work properly" or figure out some combination of aftermarket parts that can make a custom fuel cell that goes into the stock location work.
  • My sending unit was acting goofy.... it "works" but you're never really 100% confident that it's not lying about the fuel level.
  • The wires coming out of the pump hanger have been repaired several times, to the point of being too short now to repair again without doing something "rather creative".
  • Long ago I overtorqued the o-ring'd pump hanger hold down bolt and broke it.
I am no welder (yet). So making my own fuel tank will not be an easy task. I had a friend weld a plate over the hole that the broken o-ring bolt (that I could not find a replacement for) used to cover.... but now the pump is floppy without having support that the o-ring'd bolt provided. I got rid of a place where a leak could potentially happen but I also got rid of structural rigidity of the installed pump hanger.

My requirements would be:
  • Retains fuel level sending unit functionality or replaces it, allowing me to have a fuel gauge that works on my dash.
  • Holds at least the same amount of fuel that the stock tank did... and bonus if it can hold more.
  • Not require an external pump, but an external surge tank mounted in the trunk area would be ok since it can be small.
  • Some degree of crash safety that is "standard" on a fuel tank. I know getting a plastic one is probably out of the question.
I hope for this thread to be a place where people in my situation (we're not all AWD drag strip guys) can brainstorm some solutions because I am surely not the only person with this issue. If anyone, with experience, can guide me in what I would need to learn/pay attention to for making my own replacement tank, that would be helpful and appreciated. I would not be opposed to using something from Radium if it could be installed in a way that allows me to retain my hatch/trunk space. They do offer a 22 gallon option but I am not sure about the dimensions and if this would fit where the stock tank goes.

 
Last edited:
How about restoring yours?

If your internals are not corroded the rest can be restored nicely. The sending unit will need to be refurbished which is possible to do even on an old unit as long as it has a good starting point. Wiring can be fixed and made good on the chassis side to a high standard.

You likely will not find a bolt in option and less for the FWD.
 
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