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  #1431  
Old 11-13-2019, 07:44 PM
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There are 2 emission control devices that go in the fuel tank. One is for vapor recovery, the other is a float type device that monitors fuel level while filling the tank. I originally intended to mount these in a remote canister but the float has to have direct contact with the fuel. So, I had to drop the tank and make a dome that holds the float partially sunk into the tank. During refueling, when the level rises to within an inch from the top of the tank, the float will close. There is a hose that goes from the float to the filler tube that signals a change in back pressure that stops the gas flow from the refueling nozzle. There's no way I could have made this work reliably with a remote installation so I pulled the tank out and made a dome shaped riser that will hold both devices.


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This is the apparatus that will mount on the riser. The one on the right is just a filter and a vent tube that runs to the vapor recovery canister. The one on the left is the go/no go float


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Unfortunately, when I was removing the tank, I broke the fitting that the fuel line connects to. It is part of the upper plate on the fuel pump and I don't want to try some sketchy repair. The fuel pump is knocking out 55 or 60 PSI and this fitting is open to air. If the repair failed it would be spraying fuel all over. I thought I might be able to find this upper plate separate from the pump but no luck. I had to order a new pump. It was a careless mistake and it co$t me quite a bit. I won't see the new pump for a few days so I'll start on the exhaust in the mean time.




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Last edited by Jack 1957; 11-13-2019 at 07:50 PM.
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  #1432  
Old 11-25-2019, 01:24 AM
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Such headaches. My fuel pump is lost somewhere in the purgatory called USPS. I wanted the gas tank back in the car before I bent up the exhaust pipes to be sure about clearance but I'm still in the process of locating my pump. I have the front half of the exhaust done and installed. I used the CTS catalytic converters and added full quiet mufflers. The exhaust passes through the X member so none of it hangs below the frame. (Picture sucks, It's difficult to get pics under the car.)




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I moved on to the battery tray and wiring in the trunk while I'm waiting to get the tank back in and finish the exhaust. I used 16ga steel for the tray and tucked it way over on the right side. That was the original location on the CTS so I didn't have to modify the harness.
16ga is a real workout for the bead roller so I put the ribs in a little at a time. Probably 5 or 6 passes each till they were full depth. Then I tipped a 1/2" flange around the perimeter and bent up a couple perches to mount it. I used the original CTS wedge lock to hold the battery in place.


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Next I needed to make a cover for the trunk latch and the emission control canister on the gas tank that will protrude through the trunk floor when the tank is installed. I didn't get any pics of the process but it was pretty basic. I made it in three pieces. The front face and two sides. I don't have a set of tank dies for my bead roller so I used my large radius die and a grooved PU lower die to put a radius along the mating surfaces of the three panels. Tipped 3/8" flanges along the lower edges and welded it up. Most of the trim panels in the trunk will be "friction fit" but this will need a couple sheet screws.
I will get back to finishing the exhaust as soon as possible. I have a checklist 3 pages long of things like this that need to be done. The list gets LONGER as I progress! I do one thing on the list and while I'm working on that, I spot 2 more things that are not on the list. I just keep knocking em down. It's not a big job, it's a series of small jobs.


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Last edited by Jack 1957; 11-25-2019 at 01:35 AM.
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  #1433  
Old 11-25-2019, 09:05 PM
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I picked up my exhaust pipes this morning. They look good. When I can't take a car to the muffler shop, I just bend up what I need out of conduit and take that to the shop. Left and right pipes are the same so I only needed one pattern.


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  #1434  
Old 11-27-2019, 04:30 PM
crystallographic crystallographic is offline
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Quote:
Originally Posted by Jack 1957 View Post
I picked up my exhaust pipes this morning. They look good. When I can't take a car to the muffler shop, I just bend up what I need out of conduit and take that to the shop. Left and right pipes are the same so I only needed one pattern.


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Very smart linear pattern work, Jack. Reminds me of Navy training for making hydraulic lines. Very accurate for both your need and for the tube bending shop.
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  #1435  
Old 11-27-2019, 06:23 PM
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Kent, I was a machinist when I was in the Navy (MR2) but I don't remember getting into any hydraulics. I was on a submarine dry dock and submarine tender.
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  #1436  
Old 11-28-2019, 01:48 PM
crystallographic crystallographic is offline
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Quote:
Originally Posted by Jack 1957 View Post
Kent, I was a machinist when I was in the Navy (MR2) but I don't remember getting into any hydraulics. I was on a submarine dry dock and submarine tender.
Navy offered great training years ago, and maybe still does in some areas. Your thoughtful planning and execution shows a trained understanding of procedure and materials.
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Navy training used to be renowned, back when trades were great.

Happy Thanksgiving,
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Last edited by crystallographic; 11-29-2019 at 12:58 PM.
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  #1437  
Old 12-01-2019, 05:17 PM
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I'm still fighting with this exhaust system. The pipes fit right, it's just a pain working below. I saved all the exhaust hangers and insulators from the CTS to use on the new system.


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I used the original catalytic converters and pipe assembly up front, then put full size (quiet) mufflers on. Now the tailpipes. When I had the tailpipes bent, I had them done all on one plain. I knew that I might have to adjust in length and angle where the pipes spread out to go around the gas tank. It turned out that I was a little long so rather than lop 1 1/2" off the front of the pipe I took it off at the bend. That made it easier to assemble the last section with the resonator, exhaust tip and hanger. Everything fits but it's getting pretty busy back here behind the skirt.


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From below, it looks like the pipe hangs low because the gas tank isn't in yet,but if you look beyond the pipe, you can see that the frame rail hangs a couple inches lower than the pipe.


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Last edited by Jack 1957; 12-29-2019 at 02:59 PM.
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  #1438  
Old 12-05-2019, 11:15 PM
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I finally got this fuel pump business straightened out and installed the new one. The tank is back in the car and I hooked up all the vapor recovery system. I also got the trunk latch mounted permanently so I could fit the cover. While I was at it, I cut an access hole in the trunk floor and made a removable cover so if I ever have to get the fuel pump out again, I won't have to remove the tank. You can just see the access cover in the upper corner of one of the pictures below.

Now I can get back on the exhaust and finish that up.


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  #1439  
Old 12-18-2019, 02:00 PM
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I got some time in the garage so I finished off the exhaust. I couldn't find exhaust tips that would work for me in stainless steel. I didn't want chrome because I needed to cut and weld them. I ended up buying a stainless U bend and cut out what I needed.


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After I had everything cut to fit, I polished the tip and welded everything up. The exhaust is installed and finished.



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Moving on to another thing left for later. I needed to get the RDO/GPS antenna mounted. I didn't want it out on the outer body to interrupt the lines but it has to be exposed to radio waves. Being behind metal would be a problem, but back here under the rear window should be OK. I don't want anything exposed that interrupts the lines of the body. Minimal badging, long straight trim, no distractions. Smooth and clean.


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  #1440  
Old 12-29-2019, 02:20 PM
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Quote:
Originally Posted by Kerry Pinkerton View Post
Every time I look at this thread Jack, I learn something else that I did not know. Hell, I didn't even know what I didn't know.

I just found this a few pages back. See below:


Stages of Competence:


UNCONSCIOUS INCOMPETENCE - Not even aware of how little you know.


CONSCIOUS INCOMPETENCE - Realization that you know nothing.


UNCONSCIOUS COMPETENCE - Very little experience but think you know a lot.


CONSCIOUS COMPETENCE - After years of learning, you're good at what

you do but never completely satisfied.
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Set a Goal So Big That You Can't Achieve It Until You Grow Into The Person That Can.

Last edited by Jack 1957; 12-29-2019 at 02:45 PM.
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