Weld on caps for fuel tanks?

[julianf]

I want to put a defender 90 tank into my defender 110.

The 90 tank has a filler at the rear, which would end up in entirely the wrong place.

My plan is to chop off the tail that the filler pipe would normally slip over and weld it up, and then chop a hole in the top of the tank, and weld on a filler cap.

...like the military series tanks. Of which I even have a knackered one of and could possibly desolder the filler spot from.

But I thought I'd just buy a new one rather than messing about as I don't have a great deal of confidence in the old series cap seals. Forum reports suggest there were various revisions and, really, I'd rather it just worked.

Alloy caps are all over, but mild steel not so common.

I found this in stainless -

Weld On Large Stainless Steel Filler Neck with Locking Cap Truck Fuel Tank WTSS | eBay

Ideal for welding onto a vehicle fuel tanks especially truck & lorry tanks. Large Weld on Stainless Steel Filler Neck End. One Piece Stainless Steel Weld on Filler Neck. Filler Neck Height 78 mm.

www.ebay.co.uk

Which would work, but am I just being a skintflint? I'm not sure I was planning on spending £45.

I guess I could go chop up another tank but then I may as well chop my knackered series tank.

I was expecting them to be all over eBay, and they are, but only in alloy.

Anyone know somthing I don't?

Thank you.

(this is for diesel)

 

[jsf55]

Just buy a second hand pipe and cap like this .... ?

Pardon our interruption...

 

[Popcorn]

Merlin Motorsport do weld on alloy necks and caps

Weld On Alloy Fittings from Merlin Motorsport

Quality parts, spares & racewear for all Motorsport needs. Huge stocks supplied worldwide. Fast delivery. Professional service. Call us for technical help

www.merlinmotorsport.co.uk

 

[maroon]

I'd be interested to know this too. Radiator and header tank ? storks? aswell. There must be somewhere that does them. They do them for exhaust flanges (to save buying grands worth of tooling)

 

[julianf]

Merlin Motorsport do weld on alloy necks and caps

Weld On Alloy Fittings from Merlin Motorsport

Quality parts, spares & racewear for all Motorsport needs. Huge stocks supplied worldwide. Fast delivery. Professional service. Call us for technical help

www.merlinmotorsport.co.uk

Alloy are all over the place, but the 90 tank is mild, so id need either mild or stainless.

I guess most custom tanks are alloy, hence the massive abundance of alloy caps vs steel.

 

[julianf]

Just buy a second hand pipe and cap like this .... ?

Pardon our interruption...

I'd be interested to know this too. Radiator and header tank ? storks? aswell. There must be somewhere that does them. They do them for exhaust flanges (to save buying grands worth of tooling)

I looked at used defender parts also, but they seemed to be expensive. It seems like the sort of thing i should find a truck in a breakers and get the grinder out. My last visit to "that sort" of breakers yard gave me the fear though (they were stacking very close to where i was underneath a donor car)

I reckon that midgit one looks chromed? I guess it would grind off, but maybe i should just throw the extra £15 at it.

 

[James1979]

Check the boaty places or HGV factors.

This one is slightly cheaper and they sell it in alu, stainless or mild

Weld-On Metal Filler Neck with Locking Vented Cap - Float Your Boat

Large weld on filler neck and cap Filler neck available in either stainless steel, mild steel or aluminium Heavy duty locking black cap

floatyourboat.co.uk

Try ASAP Supplies in Beccles or Dingbro Trucks

 

[8ob]

A ninety tank sits very close to the removable access panel under the seat, thats going to need to be a very shallow filler neck, also need to think about venting the tank.
Cant see the need for the caps, just needs a disc made and trim back/blank off the existing steel filler pipe. That will weld.

Bob

 

[James1979]

A ninety tank sits very close to the removable access panel under the seat, thats going to need to be a very shallow filler neck, also need to think about venting the tank.
Cant see the need for the caps, just needs a disc made and trim back/blank off the existing steel filler pipe. That will weld.

Bob

Yes I had to re read the OP twice but you are right.

Why have a redundant cap that’s just going to cause issues in the future!

If you can’t weld the blanking plate on, you can bond it. Or just put sealant on and rivet it

 

[julianf]

I want to be able to fill it with different fuel to the main tank. So need the filler.

It appears to fit, according to the photos in this thread, which I'm copying -

Reb78 read --> 90 fuel tank in 110 CSW

Reb78 asked me to post this so blame him if it bores you Inspired by the blog post on Stonefisks site I decided to try adding a 90 tank to my 110 CSW.... Right first things first remove all 34 rivets holding the under seat toolbox in, drilling is easiest but if you have carpet stuck in place you ...

forums.lr4x4.com

 

[julianf]

A ninety tank sits very close to the removable access panel under the seat, thats going to need to be a very shallow filler neck, also need to think about venting the tank.
Cant see the need for the caps, just needs a disc made and trim back/blank off the existing steel filler pipe. That will weld.

Bob

The one I have on my scrap ex mod series tank is really shallow. I think it's probably the same part as the 101 cap.

If I was confident of the seal on those I'd just use that. My 101 has never had the gasket in it, but it's diesel and it's never going to spolsh out up the (extended in the ambi) filler neck.

But a 90 underseat with a wide bore cap directly on the tank is probably more than I'd trust.


Anyway, I guess I'll just got for the £40 one. I was just thinking I may be missing something.

 

[Bornfree]

How about a hydraulic tank cap.

 

[julianf]

How about a hydraulic tank cap.View attachment 381305

Thank you. Are hydraulic systems sealed? I'd imagine there are some pressure changes with temperature but I'm thinking maybe that is just taken up with an air space?

I mean it says "breather" so I'm guessing so?

 

[Bornfree]

Thank you. Are hydraulic systems sealed? I'd imagine there are some pressure changes with temperature but I'm thinking maybe that is just taken up with an air space?

I mean it says "breather" so I'm guessing so?

Most hydraulic systems run with some positive pressure you normally get a little whoosh when you open a hot system cap. But I have used these caps on diesel tanks before so they must vent vacuum.

 

[Wildefalcon]

How much of a hurry are you in? I've a series military under seat tank that is likely to be surplus ( somewhere) that I can cut up.

 

[OJCar]

If your 110 is a pick-up, there is an underseat 110 optional tank that has its filler neck in the same position as a Series underseat tank.
Then you could just fit a civilian Series type Filler Assembly.

Part number for the 110 optional tank is ESR4132

https://www.island-4x4.co.uk/fuel-tank-extra-pick-esr4132-p-3068.html

 

[julianf]

If your 110 is a pick-up, there is an underseat 110 optional tank that has its filler neck in the same position as a Series underseat tank.
Then you could just fit a civilian Series type Filler Assembly.

Part number for the 110 optional tank is ESR4132

https://www.island-4x4.co.uk/fuel-tank-extra-pick-esr4132-p-3068.html

Yep. Mine is a station waggon. Ive looked at that tank a number of times, and i think it would be a better option than doing the 90 one, but...



If you read the detail on the thread i posted ( https://forums.lr4x4.com/topic/76901-reb78-read-90-fuel-tank-in-110-csw/ ) what the chap has trouble with is the back of the tank conflicting with the seat belt mounts that are different on the CSW. The backs of the mounts are what are shown in this photo -

So he has made up those two cylindrical spacers that you see on the outrigger to offset the tank forwards a fraction (38mm he says) in order to clear those bracket things. He also comments that the bolts protruding clear of the captive nuts on the brackets are ground off flush too, as its that tight.


He then has to mess about making up a custom front mount as the front of the tank is then that little bit too far forwards to use the standard outrigger bracket.


I dont think ESR4132 offers any real advantage over the 90 tank for the station waggon. Both have the same problems of needing custom mounts and having to be chopped about.

How much of a hurry are you in? I've a series military under seat tank that is likely to be surplus ( somewhere) that I can cut up.

This tank is, however, so far as i can tell, the same as the part number that was given as the "optional" aux fuel tank for the pre-defender station waggon. I have a knackered one here (beyond sensible repair - probably easier to remake from scratch, which ive considered) and it fits fine, but looks pretty odd from the outside (hangs down further than i think the 90 tank does, and is very square). I was planning on using that part until i test fitted my knackered one, and it just looked odd/wrong.

Thank you ( @Wildefalcon ) for the offer, but, yeah, i have the cap (mentioned above ) and i guess i may end up using it, but im just not convinced that they ever seal that well, so i may just spend the £45 and be done with it!

 

[Morrisman]

I've got one I bought from a custom bike parts shop 'Custom Fasteners', 20 years ago. Well, I bought 2 and used one on a hot rod tank, the other 'spare' is somewhere in the shed. A pressed steel neck, with a chrome vented cap that screws on. They don't seem to sell anything other than nuts and bolts nowadays though.

Custom Fasteners | Chrome & Stainless Steel Nuts, Bolts, Washers & Screws

Custom Fasteners are suppliers of a huge range of chrome plated and stainless steel fasteners in Metric, Metric Fine, UNF, UNC, BA, BSF and BSCY (cycle) threads. We have a vast selection of sizes available and we are continually expanding our range.

www.custom-fasteners.co.uk