Today, I installed the new gas tank into the refinished Mustang floor. Before doing so, I took advantage of the extra space to install the bulkhead fittings, fuel filter, and connected the fuel lines. I need to fully tighten and secure everything but those initial tasks are far easier done without the tank installed.
There was some original sealant between the tank and the floor which I emulated using some 3M butyl rubber strips (#08578). This sealant is probably the best that you could get for this job. That said, I hesitated a little using it as I know it will be an incredible pain if the gas tank needs to be removed in the future.
I bolted the new tank in place using a set of Scott Drake (C5ZZ-9002-MK) reproduction screws. I used the replacement rubber filler hose that came with the tank as the original was hard as a rock. I cut it to fit (3.5") and then installed it with a set of Scott Drake (C5ZZ-8287) clamps.
There are little vertical bumper pieces that can be installed below the rear bumper. I've not had them in place and don't have interest in them. I used reproduction bolts I had that matched the originals but used flange nuts on the back of each. I did this in part to fill those holes but the two going down through the gas tank at the back at the car also serve as the ground for the gas tank and sending unit.
With everything installed and tightened into place, I connected the sending unit, power to the pump, and a dedicated ground for the pump. I then secured all the wiring with some 1/4" Tech Flex braided wire covering to help keep is safe. I now need to find something that will cover the tank and help protect the lines and the wiring as I tend to put things there when going on long road trips.
The following is what I have left before I could try to start up the car for a test drive:
- Confirm under hood wiring is secure
- Plug all wiring into the Sniper throttle body
- Connect the battery terminals
- Confirm fuel lines are all secure
- Confirm all fuel lines are tight
- Connect the fuel vent
- Connect throttle linkage
- Fill with gasoline
These are the things I'd like to come back to after the test drive is complete:
- Build a bracket for the filter behind the throttle body
- Build brackets to hold the fuel line under the car
- Insulation for the top of the fuel tank
- Rewire and dress up underhood wiring
- Run fans with the Sniper system
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