Next thing was to get it running again. I purchased an aluminum RCI 15 gallon fuel cell from Summit with the GM fuel level sender in it already. I chose this cell because it had a screw off lid not the aircraft style, fit well into the space I had (or so I thought) and it had the GM sender so the factory gauge would work.
This is probably one of the better pics of the fuel cell installed.
So I got the fuel cell and went to sit it in place and it would not fit. The cell was a bit longer due to the welds in the corners and would not drop between the frame rails of the truggy. Since I bought the fuel cell powdercoated red I did not want to grind the welds smooth on the cell. On to plan B. I heated the section of tubing that would not let it drop in until it was cherry red and slightly flattened it. After I did this to both sides it fit great. You can hardly tell the tubing was flattened.
So the fuel cell sits on a 10 gauge plate and then there is another 10 gauge top plate. I will use all thread to tie these together and sandwich the fuel cell in place. Right now a ratchet strap will suffice.
On to the plumbing. AN fittings were new to me so I got to find out how quickly these 5$ and 7$ fittings add up.
The truck was a dual saddle tank truck with the selector valve. The selector valve is at the back of the cab on the passenger side frame rail. I removed the selector valve and found a 6 inch section of rubber hose in the feed (3/8" ID rubber) and the return (1/4" ID Rubber) right before the hard lines start. I decided this would be a great place to splice in. I used all Summit brand AN fittings and Summit brand -6AN Braided hose. I found the AN hose easy to work with when using the right tools. I used a grinder to cut the hose cleanly. For the vent line I will just use fuel hose over to a fuel filter. For now it just has a short section of line on it.
I was concerned how to prime the truck to start it after it had not run in over four months. These 6.2s do not have self bleeding injectors and I did not want to air lock it. So I used a trick I read somewhere. I dialed my air compressor regulator down to 7 PSI and I unscrewed the spin on fuel filter and proceeded to pressurize the entire fuel system after I filled the fuel cell through the rollover vent until diesel came spewing out the screwed off filter all over me and my garage floor.
After I cleaned up all the diesel I proceeded to try and start it. Oh yeah I also took the slip yoke off the driveshaft and put that back in the transfer case so I didn't spew fluid out when I started it. Hit the glow plugs twice and it started right up and never missed a beat since. The truck can sit for a week and will start right back up. I am digging the straight pipe V8 Diesel sound but it is a bit droneish in the cab for a long day of wheeling.
I now could move it out of my garage under its own power for the first time in 4 months. By move it I mean by driving the front wheels in four wheel drive because there is no rear driveshaft. Also not much for brake pedal feel because of the whole no rear brakes. I will be switching out the factory 205 for the Atlas in the future so driveshafts will wait until that happens.
Oh and just my luck the fuel sending unit that came with the fuel cell was no good and just read open all the time. Summit replaced it and now it works great with the factory gauge.
Almost caught the build thread up with how the truck sits right now.