Termi tank in a v6/GT/Mach 1
02-28-2009, 06:54 PM
#1
Termi tank in a v6/GT/Mach 1
Ok guys, I did it. It took about 5 hours of work, 1 hour was wasted repairing a wire I damaged on the float assembly. A Termi tank can be bought, used, for between $350-600, new for around $1000. The Termi hat runs around $350-500. The reason for doing this mod is to save the cost of the Termi fuel hat, but still having the benefit of the Termi baffled gas tank.
A V6/GT/Mach 1 (known as "regular" from here on)pump assembly will work in a termi tank, provided you are very brave and knowledgable about how the float assembly and everything functions.
Pieces required
1. Termi gas tank
2. Complete fuel pump assembly from regular stang
3. Regular gas tank that is going to end up with 4 holes in it.
4. Patience, understanding, and skill
Basically the Termi pump assembly is all mounted to the hat. The regular pump assembly is clipped into a "basket" and seperate fdrom the hat, only connected by the wiring harness and fuel hose.
Once you've removed the fuel pump assembly from the regular tank, you will see 4 spot welds holding the "basket" in place in the bottom of the tank. Flip the tank over and use the smallest drill bit that will drill out the welds. When all four welds are drilled the basket can be removed from the tank.
Once the basket is out, trim all 3 of the flanges at the bottom of the basket that look like bolts should go through them. Trim them as flush as possible because every little bit helps. them at the top of the basket, trim the "guides" down to the height of the clip retainers for the assembly. Remove the float shaft from the float sensor.
Place the basket into the termi tank and orient it so that the float assembly would be facing straight to the rear of the tank. there is a notch molded into the basket for the float sensor, and it should have on of the straight edges facing rear and the other to the passenger side of the tank. Orientation is everything.
You now have to modify the float rod to extend out of the baffle. It can be bent to extend out and still have full range of motion. It took me about 2 hours to get it perfect. Just play with until it's perfect. once it all works with the basket location, and float assembly then you can attach the basket to the tank.
You can either spot weld it to the bottom or do like I did and JB weld the basket to the bottom of the tank.
Once the basket is in place, reinstall the pump assembly and hat and re-install gas tank.
I will not include pictures of this because it's far too complicated for just anyone to perform and involves possible permanant damage to at least $1500 in parts. This mod is also NOT reversable.
A V6/GT/Mach 1 (known as "regular" from here on)pump assembly will work in a termi tank, provided you are very brave and knowledgable about how the float assembly and everything functions.
Pieces required
1. Termi gas tank
2. Complete fuel pump assembly from regular stang
3. Regular gas tank that is going to end up with 4 holes in it.
4. Patience, understanding, and skill
Basically the Termi pump assembly is all mounted to the hat. The regular pump assembly is clipped into a "basket" and seperate fdrom the hat, only connected by the wiring harness and fuel hose.
Once you've removed the fuel pump assembly from the regular tank, you will see 4 spot welds holding the "basket" in place in the bottom of the tank. Flip the tank over and use the smallest drill bit that will drill out the welds. When all four welds are drilled the basket can be removed from the tank.
Once the basket is out, trim all 3 of the flanges at the bottom of the basket that look like bolts should go through them. Trim them as flush as possible because every little bit helps. them at the top of the basket, trim the "guides" down to the height of the clip retainers for the assembly. Remove the float shaft from the float sensor.
Place the basket into the termi tank and orient it so that the float assembly would be facing straight to the rear of the tank. there is a notch molded into the basket for the float sensor, and it should have on of the straight edges facing rear and the other to the passenger side of the tank. Orientation is everything.
You now have to modify the float rod to extend out of the baffle. It can be bent to extend out and still have full range of motion. It took me about 2 hours to get it perfect. Just play with until it's perfect. once it all works with the basket location, and float assembly then you can attach the basket to the tank.
You can either spot weld it to the bottom or do like I did and JB weld the basket to the bottom of the tank.
Once the basket is in place, reinstall the pump assembly and hat and re-install gas tank.
I will not include pictures of this because it's far too complicated for just anyone to perform and involves possible permanant damage to at least $1500 in parts. This mod is also NOT reversable.
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mrappe
V6 (1994-2004) Mustangs
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