Tag Archives: repair

Petrol Tank Woes

suzuki super carry fuel tank pickupI thought the fuel tank issue would be simple to fix, there’s a page on it all here. Despite fixing up all the external pipes, coating the inside with sealer and painting the outside, there is a hole in the pickup pipe inside the tank. This is drawing air in with the fuel making for a weak mix and serious problems going up even mild inclines.

To address the issue, I’ve been on the lookout for a second hand tank, however these are as rare as rocking horse droppings. My efforts to source a tank have involved reaching out to Dellboy (who has none left) and those online agencies that contact 250 breakers by email for the part you need. Not a sausage from them…

I toyed with various options like a temporary tank in the footwell for now, or even making a tank from scratch. However I need my van in just over a week as it’s holiday time! So…  I caved in today and handed over £326.11 to the local Suzuki dealer, the new tank will be with them tomorrow. Allegedly.

I’ve explained to the bank manager that I have two weeks off at Xmas so will fabricate a new tank from scratch in stainless steel of approx 48 litres. That will mean the nearly-new tank will go to someone else at a bargain £250. The old tank will be split, repaired and resealed – i’ll want around £90 for that as it costs a lot of money to paint and seal, or may just keep it for a rainy day.

Engine fully built

IMAG0829The engine is now fully built, I’m just waiting for the weekend to put it back into the van.

On the technical pages you can see how it was all taken apart and fixed up, the only bit I haven’t written in the blog yet is how it all went back in.

Links: Dismantling, Repair, Reassembly

There are also a few Youtube links of me building the engine up. This uses a time lapse video and in total there is 9.5 hours of work which went into putting the basic engine together.

Part 1: https://www.youtube.com/watch?v=b_-aUr82sFg
Part 2: https://www.youtube.com/watch?v=rZEy-RdWIWY
Part 3: https://www.youtube.com/watch?v=8v5eIZDDHFI