Jordis 1988 Samurai (Re)Build

Post by **Jordi** » Sat Jun 23, 2018 1:13 pm

Fuel filler cap welded on.

Sender unit bolted in. I used self drilling hex head screws from screwfix and was well impressed with them given i was screwing into 2mm steel.

Welded on the other end cap and made a start on tidying up the welding. Some parts welded beautifully, others not so great.

I am going with the presumption it will not be fuel tight but based on recommendation from a few mates i’m gonna definitely line it with liquid tank.

It’s slow progress due to work and family commitments but it is progress.

Post by **Jordi** » Sat Jun 23, 2018 4:14 pm

4 120mm x 40mm steel plates. Clamped together, drilled and bolted together.

Some metal folding later.

Where the rears will bolts to the existing cross member.

Next step is to make two brackets to weld onto the chassis to support the rear of the tank.

ROBBIE · Post by **ROBBIE** » Sat Jun 23, 2018 9:12 pm

Looking sweet

donkeychomp · Post by **donkeychomp** » Sun Jun 24, 2018 11:47 pm

Looking great Jordi. Is the tank kinda the same size as an SJ one? If not your fuel gauge might be wrong...if it ever worked to begin with lol

ROBBIE · Post by **ROBBIE** » Mon Jun 25, 2018 10:58 am

Looks the same shape size as that came with my LJ

Post by **Jordi** » Mon Jun 25, 2018 11:00 pm

donkeychomp wrote: ↑
Sun Jun 24, 2018 11:47 pm
Looking great Jordi. Is the tank kinda the same size as an SJ one? If not your fuel gauge might be wrong...if it ever worked to begin with lol

Only ever worked between half and empty

It is a bigger tank but is pretty much the same depth so the standard sender unit will work fine it.

I honestly can’t remember its capactity. I sat for ages working it out too.

Bought a new sender from one of those indian ebay sellers too, hoping that work properly.

Just on researching the tank sealers now. So far the POR 15 seems most commonly used with generally good reviews.

donkeychomp · Post by **donkeychomp** » Mon Jun 25, 2018 11:26 pm

Yeah POR is great stuff I've used it on bike tanks.

Post by **timwilks13** » Tue Jun 26, 2018 12:55 pm

Just drive at high revs all the time and you will use the fuel up before it has time to leak. Work smarter not harder.

Also grand job of the tank, will look good all finished and painted up!

andyrew · Post by **andyrew** » Wed Jun 27, 2018 11:39 pm

Looks good dude.

Post by **Jordi** » Mon Jul 30, 2018 5:49 pm

More progress.

Brackets welded onto the tank and chassis brackets made and welded on.

Suzuki Club UK

Jordis 1988 Samurai (Re)Build

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