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Day 17

Next is the gas tank. I wanted to re-use my YJ tank so the fuel fittings and the level sensor would all be the same, plus I don't have to buy another. I also wanted to mount it as high as possible, taking advantage of the 2" body mount that I will retain. But as you can see below, the TJ crossmember is very much in the way.

The body mounts on this crossmember are at the right location for the YJ tub, so I wanted to keep them there. I chopped out a huge piece from the center. A 1"x1" square tube fit nicely underneath the front remaining lip, and was at the right location for the YJ tank skid plate. Then I cut more out around the body mount so the tank could slide up. I replaced the lost strenght with 1/4"x1" bars around the rear and inside walls.

I still needed to go down 2" on the front mount, so I added a 1"x2" rectangular tubing spaning to underneath the frame rails. This will also add a lot of strenght in case I rest the Jeep on the gas tank.

For a rear axle limiting strap I chose to use a piece of a retired tug strap. The top is passed around a 1/4" bar against the new gas tank support, this makes it easily adjustable. The bottom is clamped beneath a 1/4" bar.

And here it is all finished. Also note I put my external fuel pump and filter on the new mount.

Day 18

Now it was time to swap over the engine and tranny. Nothing special here, just disconnect everything between the engine, body, and frame. I removed the windshield, hood, fenders, grill, seats, and tools to reduce the weight and bulk.

We put an axle stand under the front cross member thinking the weight of the engine might make it tilt forward once the body is off. What I did forget is that the exhaust has a mount to the body, so when 6 guys pulled the body off and started going back, the axle stands holding the frame tilted back and the frame fell to the ground at our feet, shortly followed by the body tub. Luckily no one was hurt, and the only things damaged were axle stands crushed underneath.

After catching our witts and disconnecting the exhaust, we managed to move the body outside on blocks.

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