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jeff_hooper

Rusted out petrol tank

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1996 V8.

Left side fuel tank needs replacing. I've stripped it all out and have the tank free but there is no way its coming out with the engine in situ.

I need a lot more space (at least 2 inches) and it looks like an engine out job? or can dropping the engine slightly and taking the top covers off make enough difference? If so any advice?

I have considered smacking big dents in the tank till it comes out (a bit radical, a bit desperate and not convinced it would work anyway). Then I can get a smaller custom made one to go back in. I'm told there a local firm that make one off custom design tanks for race cars and it would also be much cheaper than

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I like the idea of smacking big dents in the side of the tank! Do it in a public place. I'm sure it would cause a bit of a stir, may even make the papers. I can see the headlines now.

"Crazed man attacks Esprit with a sledgehammer in a desperate attemp to free himself from a rusted tank!!" ;)

DO IT!!!!!


Chunky Lover

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Is Jeffs the first V8 with rusty fuel tanks in the world?

Easy with the hammer, big guy. Im sure you could get the tank out by undoing the engine mounts and moving the engine over(like on the other Esprit models) or as you have surmised, pulling the valve cover etc. Good Luck!;)

Edited by WayneB

SUNP0003-1.jpg

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Guest teigan

personally, i would weld up the holes in the damaged tank; for my superpower is economy.

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Jeff,

Can you send me full details of the problems with the Tank. I've been working with Lotus in regard of the rusting tanks and need as much information as possible. It might be to your and other owners advantage to get as much info as possible. Please contact me as soon as possible. We might be able to help in some way.

[email protected]


kato

lew_small.gif

http://www.lotusespritworld.com' target='_blank'>

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Latest update on this problem. I've finally got around to doing the job of getting both tanks out, pasenger side is leaking and its prudent to look at the other side just in case.

As well as just stripping everything out that's obviously getting in the way. You need to take of the rocker covers, plenum chamber, fuel rails and also trim a little fibreglass of each side of the top of the bodywork, its the last bit hidden by the side trim piece so it doesn't really matter but when you look at it it doesn't follow teh line of teh roof and just sticks down a few millimetres too much. I took a strip off about 5 mm deep and tapering backwards over 10 cm to nothing. It makes all the difference.

Drivers side came out fine but on the passenger side the the balancer pipe protruding on the bottom of the tank is the final problem. I gave up and got my arm in with a big hacksaw and cut ot off.

Both tanks look in similair condition underneath with a big damp rust patch in one corner and a very damp piece of soundproofing that's more water damp than petrol. So I was right to get the drivers tank out at the same time.

Next is repair at a specialist, any suggestion for the North West/Manchester areas? from what I have read 'renu' coating inside and out by the specialist after the steel is reapired of course is the way to go? I'm also planning to get them to put on a banjo type (?) fitting on the bottom of the passenger tank so that the balancer pipe issue is solved for reinserting the tank in the car.

My plan is to part fit the pipe but turned through 90 degrees so I can insert the tank past the tightest part (over the engine). I should then be able to reach in (like I did when the pipe was sawn off) turn the balancer pipe to its correct orientation and tighten the fitting. Okay, its introducing an extra joint under the tank but it will be an all steel fitting and because of its size will be very robust so it shouldn't be a problem. This should prove a simple mod that doesn't affect anything else.

Any thoughts please on alternative material for the underside of the tank instead of the superbly designed water retaining sponge stuff. Or maybe just leave it out altogether?

Jeff

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I checked out door mats at the hardware. Found a soft, spikey, plastic one. Cut it to shape and mounted spikey side up to enable water easy drainage. That was 18 months ago so should know in a few years how well it works.


DanR

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Jef

Had rusted tanks in my '83 Turbo.

Took them out 2 weeks ago and had stainless ones made.

Two shiny new stainless tanks are standing in the garage ready to go in this weekend. Had the same problem with the left tank's balance pipe and followed the same hacksaw route. The new tank has a bolt-off balance pipe.

I am going to use the same spunge (top and bottom) as stainless doesn't rust.

Good luck with yours.

My tanks had evidence that they were out before, obviously by one of the previous owners. Stainless ones in 0.9 mm is not heavier and will last forever. Pity he didn't do it properly in the first place.

Duncan

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Jef

Stainless ones in 0.9 mm is not heavier and will last forever. Pity he didn't do it properly in the first place.

Duncan

<{POST_SNAPBACK}>

LOL yes goooood point, that its wasn't sorted properly first time. I'm having my tank repaired and then 'Re-nU' coated. which is a coating with a lifetime guarantee... about

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Jef

Had rusted tanks in my '83 Turbo.

Took them out 2 weeks ago and had stainless ones made.

Two shiny new stainless tanks are standing in the garage ready to go in this weekend. Had the same problem with the left tank's balance pipe and followed the same hacksaw route. The new tank has a bolt-off balance pipe.

<{POST_SNAPBACK}>

Duncan

I am about to take my tanks out to have them coated.

Where did you get the stainless tanks made and how much did they cost?

Nigel

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Jeff / Nigel

Sorry for the long delay. Been a madhouse at work.

The tanks are now fitted snugly in place on the Esprit.

From a size point if view they fitted exactly. They copied the the shape and roundings of the original tanks very closely.

I am in Durban, South Africa. One of my suppliers made the tanks up for me.

Both tanks worked out to approx 600 pounds (converted from rand)

Don't know if the Stevens tanks are exactly the same. (probably is)

If anybody would like a set made up I will arrainge it.

A stainless set will outlast the car. (I was worried about coatings coming off eventually)

Good luck guys.

It is not a pleasant job, but at least I know I will never have to go there again!

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I am sure I have seen an advert for aluminium tanks for the Esprit.

Can any one else remember seeing such, and if so where?

Jim

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