U-Joint Fuel Tank Shortening Kit OR info on "how much to shorten the tank"

[WinnieVan]

Hey everyone -- I think this might be my first post here, but I have a new-to-me 2000 E350 7.3L Diesel Conversion van with 215K on the clock. It had the dreaded fuel leak from the bowl and some exhaust leaks from the up-pipes, but I've cleared those up and now this thing is driving great!

There's a bit of a stumble at idle occasionally -- I imagine the in-tank screens are clogged at this mileage, so I'm going to drop the tank to do the hutch and harpoon mods and add a remote fuel pre-filter, and figured this is a good time to have a look inside the tank and clean it if it needs it.

If I end cleaning the tank, I'll probably have it shortened too since this puppy is eventually getting a 4x4 swap...

So does anyone have the U-Joint guide for cutting? I don't need the actual cap, just the guide. I'm a dog-crap tig welder, so I'll be taking this to a shop and I imagine giving them the guide would make it a very simple job. A picture of their kit is below:

If not -- how many inches need to come off the front of the tank?

I'm sure the whoever I'm paying to fab this up can measure (ha ha ha), but I just want to make sure I'll have enough clearance for a NP271 mated to the 4X4 4R100!

I'm in Bay Area CA. Love driving, so I'll come pick it up if you're somewhat local!

 

[mgmetalworks]

See the indent for the frame cross member and tank strap? The cut is made just forward of that. (Picture from google search, this is a photo from an article about Quigley)
http://www.exploringelements.com/quigley-motor-compnay-4x4-vans-are-cool/

 

[WinnieVan]

Cool. Thanks MG. Someone on Sportsmobile forum said it is 11" forward of the center of the front vent -- that looks about right from that photo too.

 

[Raul]

This is how I did mine. I had U-joint template, but since I have the 5.4 with the 4r75e I didn't have to cut that far. More details here: https://expeditionportal.com/forum/...10-e350-5-4-diy-coil-conversion.167666/page-5

 

[WinnieVan]

Cool! Thanks everyone. That seems pretty straight forward.

Did you use tank liner after welding it back up or just let it be? I imagine the welding heat would do a number to the existing coating.

Maybe I’m overthinking this.. but probably the “right” way to do it is: cut, weld, boil, recoat?

 

[CaptainBuilt]

Please make sure you fill it with water and check for leaks before installing it and adding fuel.

I did that and had a pin hole leak. So I had to drop it and do it again.

Also this is a great time to do the hutch / harpoon mod while the tank it out.

 

[tcg144]

I’m also interested in what needs to be done with the tank liner.

Anyone have a source for new tanks? Currently driving the van so was considering buying a new one to modify.