CMC fuel tank mods, fuel cell alternatives?

I just trailered home a 90% complete CMC kit. This is a really meticulous build that has sat in various stages for close to 25 years because the original owner just didn't finish it. One of the few things that has not been done on this car is the fuel system. More specifically, the mods to the tank that the manual details. Is there a better way to do this today? Like, with a commercially available fuel cell, etc.?

I guess I don't understand why I can't use the standard tank. Do I really need to cut and weld the tank like the manual shows?

TIA

Post some photos....
Most of the fuel cells I have seen just are not made in a size that will fit ....
The stock VW tank mods are easy, you can cut the filler down, scuff the mating surfaces and sub the welding (new unused tank only) using JB weld it in place..this take a total of 20 minutes to do. Remember to have a provision for the tank to vent. ~Alan

Thanks for the help, Alan. Maybe the work has already been done? I still haven't looked at this in good light, but from the photos, it looks like it might have already been cut and welded. I assumed it wasn't done since it's not hooked up.

http://lh4.ggpht.com/_7FHQQJXuE40/SoN8NVvbdiI/AAAAAAAAIHA/F2rFmQj2zz8/s800/IMG_5290.JPG
http://lh5.ggpht.com/_7FHQQJXuE40/SoN8PNbt0uI/AAAAAAAAIHE/UdWT-rtobiE/s800/IMG_5289.JPG
http://lh5.ggpht.com/_7FHQQJXuE40/SoN8Qmfji1I/AAAAAAAAIHI/Sckl_2CEglE/s800/IMG_5287.JPG

Why on earth does everyone seem to want to put the fuel filler right next to a fuse/relay panel?

The work on the tank has been done.

I would ask why someone would put the fuses next to the fuel filler.

I put my fuses inside the car.

Thanks, Michael. I tend to put fuses and relays as far away from fuel as possible, but that's just me :)

The CIP1 large capacy tank with their chrome cap fits the CMC cut out without the need to mess with hood liner. It adds capacity and needed weight to front end too. I think its about $130 + shipping now. I don't like welding used gas tanks regardless of how long they were aired out (proper way is to fill with inert gas - but still potential bomb).

I'd fill it with water if I had to weld it.

Is the tank I posted in the pictures already done? If it's done, I'll just use it. There are no clearance or fitting issues, and it looks like it's been re-welded around the filler neck. Should there be a vent on the filler neck? If not on the neck, then where on the tank?

TIA

Thanks for the help. The car needs to be completely rewired. I'm going to buy a wiring harness from VS and I'll probably pull that fuse panel into the passenger compartment, or move it to the other side of the front trunk.

It looks like it (an early VW tank) was cut and the filler brazed back on -- I don't see an air vent fitting though - perhaps the cap is vented. As you indicated I sure wouldn't want confined gas fumes that close to possibly arcing fuses and relays! Looks like you could relocate the fuse panel to above the passenger's foot area or better yet over to passenger's upper kick panel area. I'd add a rubber grommet and sealing silicon where the wires go through the fiberglass "firewall" too. To finish, that black corregated split tubing would dress up the wiring harness too.

Welding a tank full of water would be a mess what with steam and boiling water. CO2 or Argon gas is generally used. I recall a friend welding his with the exhaust pipe from his PU routed into the gas tank. It didn't explode but he had head ache from Carbon monoxide fumes.

Shuie, if you get hung up with the VS harness email me... I know it well. ~ Alan
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....I'd fill it with water if I had to weld it. NOT !

I knew a guy that owned a Sunoco station in NJ that thought filling an old tank with water and welding would be ok. ( gas can penatrate into metal) in a flash, the front section of the gas station relocated it self half way across the highway.....he didn't make it ~

Thanks, Alan. I really appreciate the help. Are the instructions okay for the VS harness? Is there a better option? Any chance you have a spare for sale from an old build?

Thanks for the heads-up about the welding also. I've welded on a fuel tank filled with water before without issue, and I know a lot of others do the same. You can never be too safe, tho. Honestly, for $130, I'd probably rather just buy a new tank since they are available. I just walked down to my garage and took another look at my tank, and I'm pretty sure it's not vented. I'll probably toss it after I get the car running.

I'm currently hoping to get by with a vented cap.

If you want a vent it would probably be easier to add some kind of fitting to the neck than to cut and weld another tank.

Is there a way to tell if a cap is vented? Mine looks pretty basic.

I'm so tempted to break out the holesaw and drill the hood for a 100mm Blau center filler :)

I was a litle creative with my tank. After washing it out forever with ivory soap and water ,I cut it in half above the flange. I them fab up a new larger section for the top. Tig welding all the joints. I salvaged the sending unit flange, added a fuel cell cap and vent with a check valve. To finish it off seal the internals and Line-X coated the exterior.Only regret was that I did not install baffles to eliminate the excessive float movement.

Joe how's that Vee rod coming ..pics? ~Alan

It's going slow . Here's the photo link
http://s241.photobucket.com/albums/ff42/Jogyver/

Gday Joe, hope you are well. What is that in your trunk? 3 little aluminum things and why 3....?

Cheers

They are a couple of wiggets!
They are my front / rear (separate)brake and clutch hydraulic fluid reserviors.