Ford Capri 2.8 Fuel Tank Replacement in Aluminium

Its pretty typical with the age of many Capri`s still either on the road or in garages being repaired or restored, that their steel fuel tank is showing signs of corrosion and maybe even perforation.

In this instance  we had been asked to replicate a Ford Capri 2.8 injection fuel tank as the old steel one was too badly corroded.

Fuel tanks were typically pressed or stamped out of sheet metal and flange welded in the days of Ford Capri manufacture. Many fuel tanks were simply “hung” from the chassis or floor pan and suffered with corrosion due to the rear wheels kicking up water, road dirt and the likes onto the mounted fuel tank. Many tanks now days are manufactured from plastics and hence do not suffer with corrosion like the Steel Capri tanks.

Obviously in some instances repair is possible. This usually means stripping the tank, removing any risk of explosion by means of emptying the fuel tank, pressure washing out and then purging and filling the tank with” inert” gas before cutting / patching / welding / repairing the tank.

Over the years I have seen many tanks repaired with “chemical metal”, which eventually still “seep” fuel, not ideal.

So if you are needing repair or replacement of your Ford Capri fuel tank, you know where to come.



Above – bottom pressings and ends tacked up, fuel swirl pot, pick up and return

Image showing top of tank ready for pressure testing

Completed tank with breather pipes fitted and filler flange taped off to stop dirt

getting into tank

Polished and cleaned up.

Any Capri experts will notice the fuel pump mounted on the wrong end of the tank ! oops

Does help if I weld the bottom to the top section of the tank in the correct orientation.

In this instance I ended up cutting the top section off, remaking and re-welding / re-testing.

Wont be making that same mistake again !

For all tank repairs and custom manufacture to suit your requirements, please contact us as below.


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