That looks stunning, it's a real testament to all the hard prep-work you did.

I can't wait to see some more progress, it keeps getting better!

That looks stunning, it's a real testament to all the hard prep-work you did.

I can't wait to see some more progress, it keeps getting better!

Cheers dude Its not that fare from up to date now but I'm determined to get this finish for summer fingers crossed.

Wow, amazing stuff. Wish I could be bothered to do this

Outstanding work mate, I hope i get to see it in the flesh at some point.

Thanks guys, I've got the bit in my teeth now so I'm really going to try and get this on the road this summer.

After laying under the polo for hours and hours and hours I decided it might be a good idea to put this car back together so I could enjoy driving as much as I enjoyed staring at it lol. So first step as we all know is fuel tank. There wasn't anything wrong with the current tank but as Russel had done such a nice job it would be sacrilege to ruin it with the old tank even if I painted it plus I had a new one in stock anyway

I wasn't happy with the finish on the new tank so cleaned it up ready for some proper protection.

Although replacing the tank on a mk1/2 polo isn't the hardest job in the world, lets face it no one really wants to do it to many times so in keeping with my original theme for the car and trying to make it fly through all future mot's I decided to go to town on protecting the tank.

First thing was acid etch (sorry no pic) and then a litre black stone chip both sides.

After It had dried I decided it would look right under the car as it wasn't glossy enough plus the satin finish might be a pain to keep clean so I out came the acid etch again just around the areas I had masked off for pipes to be connected.

Then the gloss black coat.

So here it is next to the old tank.

The old tank didn't leak but on closer inspection it wasn't far off.

I'd already put the rubber boot that fits round the top of the filler neck through the dishwasher and refitted it along with a new fuel gauge sender so next was all the little foam anti vibration pads on the top of the tank. I just carefully pulled the ones off the old tank and transferred them over.

Then all the hardware to locate the tank, I had chucked these in the dishwasher to.

The two metal clips got Vapour blasted and dipped in gloss black.

Finally the rubber strip that cushions the tank strap, this of course had been through the dishwasher.

And to hold it all in place was a freshly powder coated gloss black tank strap.

Next step was to get it in the car without scratching anything

Superb stuff. Really really impressive. I really want to get onto mine now. Grrrrr!

Superb stuff. Really really impressive. I really want to get onto mine now. Grrrrr!

Cheers mucker, Have you fitted your new tank yet?

I don't have a new tank and I'm unlikely to find one as I have the small, old style tank

Can't you fit a larger late one?

have you got a build tread going?

Yeah there's a build thread somewhere in this forum.

Swapping form early to late tank means chopping out the hand brake mech and replacing with a later one and then replacing the hand brake cables etc. doable, but I can't weld and I'm not that bothered I suppose. Just makes getting a new tank a challenge

Haha that's weird I was having the very same chat with someone on a mk2 polo page on facebook yesterday lol. A mate of mine might be able to help with your tank woes I will ask him.

My tank is fine, just be nice to have a fully treated one. Let me know though. Cheers

Ok chap, if your tanks good and doesn't leak then it might be a good idea to take it out and seal it with MS Polymer then stone chip it. You will never need to worry about it in the future that's for sure.

I always like to have a spare though if I can get hold of one

Excellent work man! always good so see a great enthusiast :)

I cant wait to start writing up my thread, keep up the excellent work!

Sam

Cheers Sam, post up a thread I'll be up for a good read.

Looking good mate.. some strong work!

Look forward to coming over and taking a closer look.

Looking good mate.. some strong work!

Look forward to coming over and taking a closer look.

Ahhhhh Andy just the man, can you get hold of early polo tanks? I think iirc mk1 and early mk2 tanks are the same "prankstar2003" may be in the market and since posting my tank refit a few people have asked if I know of anywhere that does early tanks.

Some good news for those on the hunt for an early fuel tank..VW Heritage have got some IN STOCK!

Part number 867-201-075/B, priced at £75.70 (although club polo members will get 5% off that see topic here with the details)

These aren't listed on the website, so you'll need to give us a call on 01273 444000.

Hope that helps

Right I will get on with a bit more, Before I fitted the fine new tank I needed a few replacement parts. First was the breather pipe that runs between the filler neck and the top of the fuel tank this needs to pass through a metal pipe in the inner wheel arch/rear quarter panel this pipe has been affectionately nicknamed "The pipe of doom" and rightly so as they rot out and take the inner arch with them lol. Mine was no different so after cutting the metal pipe out (sorry I never took any photos of this as I was in the zone) this left me with about and inch of good metal pipe under the seat and a hole in the inner wheel arch. All I intended to do was pass a new rubber breather pipe through the hole in the inner arch and curve it round to pass through the remainder of the old metal pipe and on to the top of the tank. First thing to do was to protect the rubber pipe from chaffing on the hole I had made in the inner arch, for this I used a thick heavy duty wiring grommet.

The Idea here is to make this a good "interference fit" this means the rubber grommet should fit nice and tight around the rubber pipe this will stop any moister working its way into the car and causing more rust in the future. This is a view from inside the quarter panel behind the interior door card if you like.

Then once its was stone chipped and painted.

Sorry its a crap shot but I didn't want to get my camera covered in wet paint lol.

This is how it looked from the inner wheel arch.

The fit was perfect, it was that tight I could only sleeve the pipe through the grommet if I covered it in washing up liquid. IMPORTANT NOTE : Don't use cheap pipe on this part as you don't want to be revisiting this again in a hurry, I used Goodyear "fuel and emissions" stuff its never let me down in the past and I've had it fitted to loads of cars over the years.

Next up was the fittings for the tank, what with the shiny new tank and powder coated tank strap the old stuff just wasn't going to cut it anymore plus I wanted to use stainless where ever I could, so here's a new tank mounting plate made from stainless with a new stainless nut and washer.

This had to be the slowest fitment of a MK2 tank I had ever done but after a while I had it in and with no damage to the floor . So on with the new stainless stuff.

A new stainless nut and washer for the tank strap.

This meant the filler neck was all lined up as well, oh and I cleaned and refitted the original waxoil grommets in the upper part of the inner arches.

I used new genuine VW stainless pipe clips instead of a Jubilee/Worm drive clips as I've found over the years that the latter rot and fall out or become impossible to work on these VW clips are a bit more hassle to fit but with the right tools they fit perfectly and look nice and original.

With that end of the breather taken care off it was time to do the simpler end, again I used a new genuine clip and cleaned the loom to the fuel sender to. I know you are never really going to see any of this but I love now factory fresh this all looked when it was done, I don't know why but I get a real kick out of these little details .

Next up was this rusty old piece of

Thats for next time, Peace out.

Edited 26 February, 201511 yr by dirtydubs

Looking good as ever. I did exactly the same with the Grommet, i cant believe there wasn't one there from factory!

I re-made the end of my drivers side Sill but didn't realize the bottom edge was shaped, so fitting the tank took ages! Hopefully yours smoothly.

Please sort out my car for me top work, I hope when I do mine it is half as good as yours, seems you have thought of everything, I dont dare inspect my tank

What special tools do you need for fitting those VW clips Dubs? C'mon, stop holding out on the details! 😄