skpyle

Hello All,

Blunt right up front question: are early and late 928 fuel tanks the same?

The fuel tank cradle on the Red Witch was found to be rusty during the PPI. I purchased a useable cradle from 928 Intl a couple of months ago. I have bead blasted and painted it. Yesterday, I removed the fuel tank cradle from the Witch. It was rustier than I thought, and pretty much unuseable.

And different from the cradle I got from 928 Intl.

Biggest problem is the side that the fuel line and electrical wiring go down. On mine, 1986.5, is is just a strap bracket, with a wide plastic cover. On the replacement I got, it is a much wider metal bracket, that is relieved with a half pipe for the fuel line and wiring.

The WSM shows the strap/plastic cover type back to at least 1984. I have seen a photo of the cradle from a 1980 Euro, and it looks just like the one I bought.

After drilling out the spot welds on the heat shield bracket on the rusted cradle, I attached it to the cleaned/painted cradle with small screws. Heat shield is not optional on 1986.5 due to proximity of exhaust pipe to fuel tank.

I installed the cradle gently, as it felt quite tight. The old cradle came down easily, though that may be from the rust weakened structure. I pushed, pulled, wiggled, and jimmied on the fuel tank and cradle to make sure they lined up with each other as I drew the bolts up. I was able to tighten down all four mounting bolts, but it feels awfully tight. My concern is stressing the plastic fuel tank.

I completed replacement of:
-strainer and seal
-hose and clamps
-fuel pump
-metal S-pipe and cap nut
-fuel filter
-pump and filter mounting clamps
-pump wiring terminal boots
-pump/filter mounting bracket rubber isolators


In due time, I plan on getting the correct fuel tank cradle from 928 Intl. For now, will this one work, or have I just set up my fuel tank to fracture from an incorrectly fitting cradle?


Photos:





Heat shield bracket to be removed from old cradle.





Old cradle









Ummm...yeah.





Replacement cradle









Note the relieved bracket/leg on the right.





Heat shield bracket transferred to the replacement cradle.





Yes, I know its butch and I should be ashamed. It is what I could come up with on short notice...





The fuel line fits OK in the relieved section of the leg, but the foam covered electrical conduit would not. I ended up cutting the foam insulation off to get the conduit to fit. I will reinstall the foam when I get the correct fuel tank cradle.





Fits OK for now. The electrical conduit is not under a great deal of compression, so I am not very concerned with it chaffing at the metal leg.





Old parts.





New parts.





Before





After




Thanks for any and all advice!

Seth K. Pyle

Guy

Great work. Yes, 78-79 cradles are different. The early ones are quite in demand but that doesn't appear to be what you received. Every late cradle I have seen from 80 and up appear like the replacement you got from 928 Intl.

They do fit tightly without any wiggle room so I would not have concern there. Looks like a great improvision

ltoolio

Looks great! I'm in the process of doing the same R&R to my cradle, so your pics give me something to aspire towards.

What replacement foam stripping did you use on the cradle?

skpyle

Thank you, Guy! I was concerned I was creating a problem. Good to know that they are tight. The improv was a little bit of sideways thinking and some minor fab work.


Thanks, Itoolio! This is the first big project off my list that I have completed. I have gotten alot of work done on alot of other things, but none are complete.

Go ahead and do it! Not as big a deal as you would think.
Pointers:
-spray penetrating oil on the threads of the bolt for the leg at the front of the fuel tank. It protrudes above the weldnut and corrodes. Mine was a bear to get out. Use a mirror to see what I mean. All the rest thread into something, less corrosion
-beware of the 'rubber' boots over the fuel pump wiring terminals. Mine were rock hard, hence 'rubber'. I replaced the boots, but had to cut and splice the wires to install them

The foam came from my local Lowe's. I tried to find some mastic tape, as in Dwayne's write up. All I found was this pipe insulation. Around $9 a box of 30'. Worked fantastically. However, the paper backing is a pain to get off, and the adhesive is demonic. Once its on, its on...








Thanks!

Seth K. Pyle