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IDMJ

‘97+ H.O. Fuel tank option

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Pete asked me to make a thread on the fuel tank setup I used on my ‘99 swap so here goes. 

 

Parts needed are:

2 pieces of 2 1/2 x 1 1/2  .120 wall rect. Tube 24” long

2 pieces of 2 x 2 .1875 angle 1 1/2” long

8 pieces of 1/4 x 1/2 carriage bolts and, psi lock nuts

2 pieces of 3/8 x 6 stainless eyebolts, washers and, Nylock nuts

stock MJ tank straps

TJ fuel tank

XJ fuel pump

 

I positioned the fuel tank in the MJ location and set the front at 1 1/2” back from the rear of the cab. Marked where the rails go relative to the tank. Put the rails in the location marked with the 1 1/2” width against the floor. Marked 4 locations on each rail that match the lower ribs in the bed. Drilled 1/4” holes in the rails all the way thru and then opened one side of each rail holes up to 3/4”. I held them up to the bottom of the bed and marked the bed to be drilled with 1/4” drill also. Mounted the rails to the bottom of the bed with the 8 carriage bolts and spin lock nuts. Then I marked the frame below the new rails for the rectangular holes that have to be cut to hold the MJ tank straps.

 

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I put the tank in position and figured out where I needed to mount the tank strap brackets. Drill a 3/8” hole in one leg of the 2 x 2 brackets and weld them in place ( or you can bolt them if you don’t have a welder) with the leg with hole facing toward the center of the bed.

165036CF-1917-4AE1-BD25-E6D226D21CBA.jpeg

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I found a guy in Boise who would modify my tank for me so, I put the tank in position and traced the top of the frame rail onto the side of tha tank. Had him move the fuel filler to the side even with the fuel door above the frame rail mark and patch the end of the tank. 

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I have a TJ tank and kept the hoses in the stock location. I used a piece of radiator hose and a bend out of a cracked stock exhaust manifold.

Check your driveshaft clearance. I had to have a 3" shaft built to clear the tank.

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I already have a 3” driveshaft and clears ok. I’d be happier with more but whatcha gonna do? 🤷‍♂️

 

I know that leaving the fill in the stock location is what everyone seems to be doing but hey, I gotta be different 😏

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On ‎2‎/‎2‎/‎2019 at 10:48 PM, IDMJ said:

I already have a 3” driveshaft and clears ok. I’d be happier with more but whatcha gonna do? 🤷‍♂️

 

I know that leaving the fill in the stock location is what everyone seems to be doing but hey, I gotta be different 😏

 

I am using a TJ cluster also. It is slightly different than the XJ cluster. I only did it to be different as well.

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I have a TJ cluster I thought about using but, the plugs in the back don't match the XJ dash. How did you get around that?

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Hmm. My TJ cluster is a ‘98 and my XJ dash is ‘99. 

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