Note – our project car here is a 1969 Chevelle. For your convenience, we’ve listed the 1961-64 Chevrolet part numbers. You can easily look up your specific year Chevrolet’s part numbers at http://www.lategreatchevy.com/
Let’s get at it…
Although you could probably accomplish this task by putting the car up on a set of service ramps, a lift going to make life much easier. Start by disconnecting the two vent hoses that are located near the top of the tank.
All that nastiness up there on the right side of this photo is the result of moisture collecting in the trunk over the years. Rotten weatherstripping was the culprit. Our Chevelle’s floor pans were very solid though, so we were fortunate. This above section of the trunk pan was another matter altogether. A fiberglass patch and some POR-15 fixed the problem area.
It’s not very often you have to remove your fuel tank, so while we’re presented with this golden opportunity, might as well use some 3M Rubberized Undercoating to take care of the area. The product description: “Rapid drying, paintable, rubberized undercoating material for rust-proofing and sound deadening. Ideal for coating fenders, quarter panels, door panels, repaired sections, welded joints, hoods, and decks”. Check out http://www.rickscamaros.com/3m-rubberized-undercoating.html
The new fuel tank. Here’s the part # for 1961-64 Chevrolet: http://www.lategreatchevy.com/full-size-chevy-gas-tank-except-wagon-1961-1964.html
The new fuel sending unit: http://www.lategreatchevy.com/full-size-chevy-gas-tank-sending-unit-5-and-16-non-wagon-1961-1964.html gets installed in the fresh tank.
Since our original fuel tank straps were just about as nasty as our tank, we used new ones– part http://www.lategreatchevy.com/full-size-chevy-gas-tank-straps-except-wagons-1961-1964.html
Here we’re getting the new tank into position. Be sure the new anti-squeak rubber strips are fitting properly between the mounting straps and tank. This is another step where an extra set of helping hands comes in handy! http://www.lategreatchevy.com/full-size-chevy-gas-tank-anti-squeak-set-1958-1972.html
The hard line coming off the tank (out of the sending unit) is connected back to the main fuel line. We also connected the ground wire leading off the sending unit to its original spot on the Chevelle’s undercarriage.
Here we are, all done. The shiny new tank matches that new exhaust system nicely! It especially looks great against the freshly undercoated trunk pan section. We fed the approximately 5 gallons of fuel we had in our old tank to our new one.