4. The original tank sports several areas affected by rust. On its bottom, there are large dents and abrasions from battles with road debris and bumps over the last 40-plus years.
5. We left the original sending unit in the original tank and installed an N.O.S. unit in the new tank. We used care while installing the sending unit so as not to damage the sock filter or float. A new retaining collar and rubber O-ring (shown) came with the replacement tank. We will install the O-ring with the sending unit.
6. Next, we installed the retaining collar, tapping it tightly into place with a hammer and large flat-blade screwdriver. This is a pressure-fit collar that compresses the O-ring as it is seated into position, preventing fuel leaks.
7. We added a sheet of Accumat to the top of our new tank to minimize metal vibration, provide an insulator to prevent metal-to-metal contact, and function as a heatshield. It is self-adhesive, and since it is pliable, it will take the form of the tank.
8. We used a soft towel to prevent any dings or scratches on the new tank as it was jacked into position. If you're doing this task without a helper, we suggest you establish a balance point for the new tank on the jack so you can install the mounting straps.
9. We installed new reproduction retaining straps next. At the rear of the GTO, they hook into pockets in the frame and are retained with a special screw passing through the strap.
10. The soft metal straps need to be slightly bent to conform to the exact shape of the tank, and then pushed up at the back end to allow the retaining bolt to be inserted. This long bolt screws into a threaded mount in the chassis. Once both bolts were started, we tightened them evenly side to side until the tank was secure.
11. This GTO restoration was re-plumbed with stainless-steel lines sourced from Classic Tube. There is a maze of tubes converging in this area, most of them involving emissions. Beside the fuel line and return line, there are vapor tubes to the canister behind the rear seat, and lines that run up to the charcoal canister in the engine compartment. Now you know why we took digital photos of the factory parts during the disassembly.
12. The new tank looks great and is ready for any car-show judge. The project only took a few hours.