924Board.org

[Kevin D]

Thanks again to Rasta for his write up:
http://www.924board.org/viewtopic.php?t=29582
I didn't have access to a welder so I had to try a slightly different approach.


My steel tank started leaking last year. It was getting embarrassing and expensive, so I took the opportunity to salvage this tank from my buddies totalled 944s2.


I cleaned up 14 years of road grime and removed and straightened the heat shield. It fit much better after being unfolded.


The PO had climbed a curb and dented the fuel pump cover. Nothing a bean bag, ball peen hammer and 5 minutes couldn't fix.


All cleaned up, repainted and fresh rubber on the fuel pump assembly.


The stock 924 strap (on right) is 1" wide. The 944s2 straps are 1.25". I was able to use the 924 strap on the driver's side, but I needed the longer 944 strap on the passenger's side to reach around the larger tank.


I just used a Dremel cutoff wheel to open the stock bracket a little to account for the wider strap. This is the before pic.


Because I didn't have all the brackets from the 944 I had to utilize the 924 bracket locations which run the straps directly back to front, whereas the 944 tank was designed to place the straps at an angle. Centered in the back and angling out to the corners of the tank at the the cross member. So far using the stock 924 mounting points with the slightly longer 944 passenger side strap seems to work OK.


The next thing was the 924 fuel pump. The 944 tank needed that space so it had to go, brackets and all. Since the plastic tank would be touching that area, I was carefull to keep the cut edges as smoothed down as possible.




I didn't have the 2 center bolt brackets to weld in like Rasta so I dropped two M10 x 90mm bolts through the back deck. I tried 95mm bolts first but they just kissed the cross member so I swapped them out for some 90mm and they were perfect. The bolts reach through those center holes in the tank and attach to some plates that hold the tank in place. The bolts dont go to the cross member. All said and done, there is just 5mm clearance between the crossmember and the tank.



The 944 line from the pump reached the filter, and I had an insulated hose that was a perfect fit from the filter to the steel line. Just like Rasta I did have to move the steel fitting towards the front of the car about 1" to clear the edge of the plastic tank.


I looped the rubber return line from the 944 tank about 4" in front of the tank so it caught the correct angle to the steel line fitting. I could have shortened the rubber hose from the tank and changed the steel fitting to better face the line, but I wanted the extra length so I could connect the hoses before fitting the tank.


That left me with the sender wires. The 924 harness was purple, yellow, brown and the 944 was green, grey and brown. The purple goes with green, yellow to grey and brown to brown.


It's a big tank and a tight fit.


But I'm glad it's done. The steel tank was rather reduced in capacity.


Plus there were actually 3 different creases that showed signs of leaking.



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'88 924S 3L 6sp RedRat
'92 Duc 900ss
'02 Duc 998 Carbon
'72 RD 350