CHEAP (and effective) DROP TANK

[LOK15]

Ok this is it...
The fuel tank from an XM falcon will slide inbetween the chassis rails. You will need to make up a support for it(ie 1" shs) which in turn gives you a boundary to seal the tank from the road and possible exhaust fumes. The fuel filler is mounted behind the numberplate(torana or kingswood hinged plate holder)which utilises a gem wagon fuel recess welded into the 's' moulding behind the no: plate which in turn allows the filler neck off a sedan tank to be used ( cut with a hacksaw )soas you may keep the original fuel cap and key.You will need an electric pump(unless TF-G mechanical pump is installed)
unfortunately.. the sender unit isnt right for a gem so when it hits 1/4 tank its usually empty.The tank sits deep in the boot and to get the true 'drop tank' look you can get a cover made up out of steel.
This whole exercise will cost a lot less than getting an alloy tank made up if you dont want to spent a heap of cash
I have given a brief description.. and am willing to give any answers to questions if problems arise. I have done 2 such conversions and have had them passed by D.O.T no worries (in qld). I hope that this helps squash all questions on what to do.. as i have tried different size tanks eg escort.. corona and others to find one that easily fits. and the XM falcon does the job nicely..( room behind the seats for those 12" subs now!!!)
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[GEm1ma has xplod gea]

sounds good , but i reckon u could use ya standard tank and just lower it in, and then put sum alloy on the bottem 2 make it look like a drop tank.

chris...

[NeWaZ]

i take it the standard gem tank will not fit between the chassis and the XM is the perfect fit?!?!

i am planning on doing this conversion very soon but umm.. where the hell do you get XM parts from??? they aren't the most frequent of cars to find at a wrecker???

help appreciated

cheers

NeWaZ

[Mark]

What do you mean standard gemini tank? A sedan tank? you cant just lay a sedan tank on its side you know. Wrong baffles , wrong fuel pump pick up , wrong sender unit and fuel filler neck from the wrong spot. A van tank fits, but requires much modification, Ive seen Lokies falcon tank conversion, looks good. Like the xui torana tanks......

[LOK15]

ford wreckers..
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[NeWaZ]

yeh thanks lok, had only checked at general wrecker so far...

would it be possible for you to email me a kind of step by step process u have used for your 2 conversions... a bit more detail than what is in the workshop, ie. mounting etc.
and some pics if possible that would be appreciated

newers69@hotmail.com

cheers

NeWaZ

[ziggz]

Can you please send me a step by step process as well

tufftg@hotmail.com

[LOK15]

i dont want to type it all out again so if you ask newayz nicely im sure he'll email it to you
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[ziggz]

thankz

[TGNVD247]

newayz can i please have the step by step conversion as well 2? thanks!

piganator2001@hotmail.com

[RUBY]

for everyone to use. like me! or email it to me breeze@myaccess.com.au
thanks guys

[LOK15]

1- buy a XM-P sedan tank.. with no holes(age is a big factor)

2-measure the front to back of the tank.. not from the edge , but from the actual tank fuel holding cell.They have a join lip which allows you to bolt it down..
Now in your boot is a factory join right at the back near the taillights on the base..( cant miss it)make a cut along this but on the inside of the line ( so the cut is not visible from the back of the car)between the chassis rails. Measure the distance from the to the inside of the boot( towards the orig. fuel tank ) , and mark the line from rail to rail..

3- DO NOT cut on this line.. but 20mm inside it.. so you have room to play with incase the cut goes a little askew.

4-You will notice that the line of the rail on the passenger side is not as straight as the D/S rail..You must cut 5mm into the D/S chassis rail.. and then use a measurement of the width of the tank to get the boot floor cut to size.

( REMEMBER) you must make all cuts smaller than needed to soas not to create a huge , hard to fill hole.


5- You will have to trial fit numerous times to get it to sit in.. use the flatness of the D/S rail as a guide.

6- Once you have it sitting snuggly in there measure all the gaps( P/S rail is curved downwards and the divot in the boot just left of the fuel pump not to forget the gap between the rails near the bumperbar brackets) and cut 1" square hollow section ( SHS ) oversize soas you can trim it down to the correct size . A little note: you will have to bend or cut the corners of the tank as it interferes with the bumper mounts.

7- make sure that your SHS sits up against the underside of the tank mounting section and the small cutouts( where bolts will eventually go to secure it) and are all lined up.Tack weld them in and double check that the tank sits flush.

8- Pull the tank out and look at all the gaps. Weld in plates to hide ( and seal ) the boot inner from the outside ( fumes will get in otherwise )

9- getting all this????

10- grab a fuel filler from a wagon and unpick all the spot welds to give a clean filler..

11- Measure ( trace ) around it against the back of the car ( behind number plate ) and mark 15mm inside of that line and cut accordingly.Make sure b4 you do this that you put the number plate there to make sure that it will cover where your cutting.Weld the filler hole inside of the boot to the car and bolt on a torana tilt down number plate holder.

12- Cut the filler neck off a sedan tank(I CANNOT STRESS ENOUGH!!!! USE A HACKSAW!!! ) this enables the original gemini cap to be used( and key)

13- Fuel lines are pretty straight forward.. so is the sender unit..

14- Bolting it down requires some more mods.. like drilling holes in your SHS and welding in flanged nuts upside down ( with the bolt in it soas not to stuff the thread) into the SHS to keep it all flush.

15- The hose that connects the tank to the filler was off a truck as the angle is very tight( radiator hose).

16- If you have a gem with the fuel pump in the tank then you will have to get an aftermarket pump whereas if TF-G you will have the mechanical pump on the head.

I hope this is detailed enough for you.. i have no available photos but will be doing another drop tank as soon as i get some time.. then i wil take some piccys.

have fun...

lachlan
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[GEMTEC]

Hey dude,
that is some very helpful info on the droptank situation and cheers. but the info that i was actually wondering about is if a wagon tank actually fits between the chassis rails in the boot. i have been meaning to go to the wreckers and measure the dimensions, but i ha

[GEMTEC]

have been too busy. thanks if your can answer my queary.
Hilly