Done With the Fuel Tank

Finally finished cutting the fuel tank out today. All the chunks above comprise about 75% of all the plastic that made up the tank. For those of you thinking I was crazy for doing it this way instead of the proper way, let me just say, you may be right. But, how long would it have taken one person without all the proper lifts, jacks, tools, etc. to remove the entire sub frame? This way ended up taking me about 5 1/2 to 6 hours. Man, did it suck though.

I'd really like to use all that vacated space for something. It would need to be something that I don't need to access regularly and can afford to be stuck away from the engine compartment. Right now the only thing that comes to mind is the DC/DC converter and perhaps the auxiliary battery. If I decide to put any electrical components in there, I'll have to build something to keep them dry and clean. Hmm... What to do...

Odds & Ends Part II

This last week has been spent doing a variety of things.

1. I've been working on removing the remnants of the gas tank, as promised. Loathsome, horrible work. Still, it's coming along.

2. Spent time measuring out and calculating how much 2/0 cable I'm going to be needing. I need to measure it out carefully because the stuff is $4.50/ft on a good day.

3. Worked on fitting the big battery box under the trunk. I have to work out how I'm going to suspend it from the frame and keep everything secure. This frame has to support just over 250 lbs of lead, so it better be up to the task.

4. While out looking for some steel to do #3, I happened to park near an automotive paint store. Though I knew I'd have to paint all the bare steel, I really hadn't given it much thought beyond picking up some spray paint at Lowes and going at it. I thought it would be nice if I could make most of the visible parts the same color as the car, but figured that would be too costly. On a whim, I stopped in and asked if there was anyway to paint some bits to match the car and not pay for a 1/2 gallon of paint, spray gun, etc. He said well I could put it in a standard "rattle can" for you. Apparently if you're in the biz, that's the lingo. I walked out with 2 cans of BMW Hellrot (Bright Red, for those of us who don't do German) for $14 a pop! I did get some primer and clear coat as well, but what a deal! This will help make things look real nice.

5. Look at the pretty sparks! Started measuring and cutting steel. I was hoping that the 10" abrasive wheel I got for my miter saw would do the trick, but no such luck. It cut through a couple of pieces then just stopped cutting. It would seem their claims that it cuts metal are a bit over stated. Looks like I'm going to have to buy a real steel cutting blade.

Odds and Ends: Part I

Spent the whole day doing a variety of tasks, and yet it felt like I made no progress!! In retrospect, I guess it wasn't all bad. I worked on getting the gas tank out. I mentioned earlier that I'm going to be cutting it to pieces rather than taking apart the entire back half of the car. It's plastic after all. Crazy, perhaps, but so far so good. Oh and yes the tank is completely empty with no smell of gas what-so-ever. Even so, I have two extinguishers at the ready.

I spent a couple hours cleaning and degreasing the engine bay. 134K miles of road grime! Now I can work in the space without looking like an oil rigger from the 1800's.

I carefully measured off and marked the area that I'm going to be cutting from the floor of the trunk. Once I get a box built for the space I will be able to suspend 4 batteries below the floor of the trunk. I can put the carpet back over it and still have space to haul lumber and what-not.

Last, I drained the power steering system. I need to remove the old power steering pump, but there's a problem. It's not attached to anything anymore and the nut that holds the high pressure hydrolic line on the pump was tightened by an angry gorilla. The bottom line is that I can't hold the pump still AND put enough torque on that bolt to break it free. I'm going to need to start pumping some serious iron, or try channeling the spirit of Archimedes.

Removing the fuel system.

Today I spent the better part of the day removing the fuel system. That included two different valves, a pressure regulator, a carbon filter, the vapor recovery system, lots of fuel lines and the gasoline (only two gallons left). The fuel tank itself isn't out yet. To remove it I have to take off the entire rear sub-frame of the car. Or, I could just cut it to bits...