Tonight was mostly about tow points and the fuel tank.
Front tow point welded on, so the rope goes through the original hoop, then the hoop goes over the new point to secure it. The big win here is that it no longer needs a shackle to secure the rope:
Now we could have just re-attached the rear towbar on the back, but that's not really good enough, as it was too low and in the middle, which is away from the chassis rails - not as strong as being close or on the chassis rails. So the front of the original towbar now bolts to one of the original fuel tank mounts and the main mounting bolts go through the rear crossmember, alongside the chassis rail. The bolts will go all the way through the crossmember and be nutted on the top side.
Obviously it's not good enough to just drill through the tube, so we've hole-sawed and the crossmember will have sleeves welded into it to ensure maximum strength:
Here's the fuel tank. You'll notice it's not attractive, but it was free.
The filler was cut out of the side of the body, then it was cut down to the cap and the neck. This will be flattened down and then drilled out to suit as the filler
The difficult bit is the pick up from the tank. Thankfully the sh*tara that's still hanging around on it had some nice metal hose that was no longer in use, so that got butchered off it. After that I cut out some sheet steel, templated the five holes needed (already got threaded inserts in the tank) with some transparent plastic and centre-popped those, and drilled them out.
Obviously welding cruddy old fuel pipe ends to a nice, big thick bit of steel is quite a challenge, so I turned the welder right down and gobbed some more material around the pipes. Once that was built up I turned the welder about another couple of settings and then burned more material into the stuff I'd built up. This avoided blowing holes in the nasty old pipe and got a fuel-tight weld above and below the plate:
There was also some plotting around the main electrical feed. We have a nice big feed out of an Audi 100, which also has a couple of auxiliary feeds, too. This is going to go to a cut out in front of the screen, from the battery in the back and then to the starter and loom feed. Removing the insulting tape from the current main starter and loom feed discovered a particularly nasty repair, but then finding these things means they're sorted out.
