Full Size Bronco Gas Tank/Groco Valve in 1990 E350/54 gallons now

VANMAN

Observer
Thought I would drop a line and explain what I did.

Followed Spencer's lead and put a 6 port GROCO valve in place of the original plastic electrical valve switch (which incidentally had one broken prong ie leaking fuel). I used ALL 3 positions. Facing rear -Rear Tank. Facing Left - Front Tank (in-between 2 mounting bolts so I can feel position) Facing forward - OFF. My faith in Humanity is less than Spencers. LOL

I also removed 22 gallon rear tank and replaced it with a full size 38 gallon Bronco rear tank -Sourced from Wes @ Classic diesel design. To install rear tank I had to move rear crossmember back about 2.5 inches. I cut off Ford rivet heads with carbide blade saws all, 3 inch by 2 .5 inch angle iron bolted to crossmember then bolted in original holes. Also the original tank rests against 4 curved sheet metal rests for lack of a better name. The rear rests had to be cutoff and also pushed to the rear. These are simple sheet metal tack welded to body. Cut them off with a saws all, made them shorter. Used sheet metal riveted to the them to rivet to body. They are only rests on top to keep Tank aligned. Seems stronger than original tack welds.

Used straps that are for that tank (ST16) Stainless all thread rod to mount tank on all 4 corners. Enlarged holes in crossmember for rear 2 rods and drilled 2 holes in front supports for all three rod.

I completely removed original plastic valve...If you use original sending units, gauges etc the valves electrical is part of a loop and has to be used for electrical or bypassed some way.


I have VDO gauges and sending units and I plan on using original switch under dash but all new wiring to read both tanks, so I removed plastic valve.

Also re[laced All fuel lines with 3/8 fuel 5/16 return lines for a cleaner simpler install. The factory fuel lines have so many different pieces it amazed me how funky they were.

Had 38 gallons total now I have 54. Also used sumps on bottom of tanks so I can use ALL the fuel if need be.

Total costs maybe $500-600 for tanks, valve, fuel lines

I know somebody is going to ask for PICs..I'll get them on here eventually...but it is pretty simple really, just some elbow grease. PS Tank doesn't stick down all that much....maybe 4 inches lower!!

I
 

VANMAN

Observer
PSS...You will also need a flexible Fuel Hose...filler opening in side of truck and gas tank are not perfectly aligned...a regular hose will crimp....
 

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