New Aux Tank Failure

[MarsChariot]

Well, this is a new one.

We were on our annual fall crawl and I kept hearing odd knocking sounds underneath that worried me no end on a very bumpy and rocky trail in the back of nowhere. But we returned without mishap and then I smelled fuel smells. Apparently the entire boss that the aux sender mounting surface is part of separated from the tank! This is a new aux tank that I thought I was having trouble getting the sender to seal on. The sender seal was apparently the least of the worries here. I have never seen this and I cant wait to see what failed when I drop it this weekend.

 

[tasker]

thank goodness you caught it!

 

[MarsChariot]

Here's the failure analysis. The narrow neck where the sender boss attaches to the tank had completely sheared off. Arrows point to the shear surfaces. The only thing that I can conclude is that the twisting stress of tightening the sender lock ring over stressed the narrow neck. No wonder I couldn't get the tank to seal. There was a crack at the collar that finally gave up and the whole thing fell off. I used the WH lock ring wrench, not a hammer and screw driver to tighten the lock ring, too. This tank was only a year old.

 

[Gupster88]

Saw this post and had to chuckle. Filled my new 23 gallon stainless EFI tank from Wildhorses yesterday so we could fire up my 75 build. Went into shop today to find fuel leaking on the floor. The seams all seem to be leaking. Bought tank new a little over a year ago. First time filling it up. Anyone else had this happen?

 

[DirtDonk]

Yikes. Somebody didn't check after welding. Which is a must-do even for seasoned professionals.
Very sorry to see that Gupster. But I see a phone call from your direction in the very near future.

PM me some of your info and I'll have Matt start the lookup to get a head start. Or just give a shout via e-mail to the sales@wildhorses4x4.com address tonight while you're thinking about it. Again, a head start on the Monday happiness.
Wishing gas was back to 1.99 a gallon right now...

Got a pump to get some of that out an into a (sealed) container so it doesn't all end up on the floor and in the air?

Paul

 

[Gupster88]

Drained it already . Yes. A phone call tomorrow. Just looked up past orders. Bought the tank new clear back in Jan. of 21. Build has been going on for a bit… Thanks for chiming in here Paul. Appreciate the help.

 

[DirtDonk]

No problem. We definitely wan to take care of it and you.
Take as many close-up and overall pics as you can while it's still wet and fresh (in your mind) so we can have a good look-see.

Thanks again.

Paul

 

[Gupster88]

And a kudos to Wildhorses. Got me a new fuel tank on the way free of charge and sent a packing label to return the faulty one. Thanks guys!

 

[MarsChariot]

Well, gosh darn. That's great. I got my aux tank from WH, but frankly, whose to say I didn't put too much force on the sender locking ring because I had a locking ring spanner wrench, not that that should be an issue, and a kind of scary issue at that when you think about it? I just thought that the whole thing was a weird failure and one that I have never seen. Si I am out 300 bucks. Anyway, next time anyone tightens up the locking ring on a new aux tank, be aware that you can apparently fracture the collar.

 

[House]

I had one fail a while back but it was at a fitting…
Wild Horses was great about sending a replacement promptly…
Thanks guys!

 

[lars]

Well, gosh darn. That's great. I got my aux tank from WH, but frankly, whose to say I didn't put too much force on the sender locking ring because I had a locking ring spanner wrench, not that that should be an issue, and a kind of scary issue at that when you think about it? I just thought that the whole thing was a weird failure and one that I have never seen. Si I am out 300 bucks. Anyway, next time anyone tightens up the locking ring on a new aux tank, be aware that you can apparently fracture the collar.

Indeed. I wonder where and by whom it was manufactured.

I replaced my then-50 year old aux tank a couple of years ago. Not because there was anything wrong with it, but because I wanted the extra capacity of the (no longer available) NWMP steel tank. I probably had the sender assembly out of the OEM tank a dozen times at least in the 25 years I'd owned it up until that point. Never had an issue. Frankly, I was astounded that the thing seemed to be in great shape, still.

Sadly, it sounds like yet another case of inferior parts made in a remote corner of the universe by a manufacturer disconnected from making a durable product.

 

[Gupster88]

Indeed. I wonder where and by whom it was manufactured.

I replaced my then-50 year old aux tank a couple of years ago. Not because there was anything wrong with it, but because I wanted the extra capacity of the (no longer available) NWMP steel tank. I probably had the sender assembly out of the OEM tank a dozen times at least in the 25 years I'd owned it up until that point. Never had an issue. Frankly, I was astounded that the thing seemed to be in great shape, still.

Sadly, it sounds like yet another case of inferior parts made in a remote corner of the universe by a manufacturer disconnected from making a durable product.

As my body shop guy always screams when something does not fit or breaks….. Damn 9 year old Chinese girl!

 

[PDQ]

Indeed. I wonder where and by whom it was manufactured.

I replaced my then-50 year old aux tank a couple of years ago. Not because there was anything wrong with it, but because I wanted the extra capacity of the (no longer available) NWMP steel tank. I probably had the sender assembly out of the OEM tank a dozen times at least in the 25 years I'd owned it up until that point. Never had an issue. Frankly, I was astounded that the thing seemed to be in great shape, still.

Sadly, it sounds like yet another case of inferior parts made in a remote corner of the universe by a manufacturer disconnected from making a durable product.

It seems like all those that used to make the extra capacity aux tanks have stopped...and those that offer the 11 gallon poly tank aren't as advertised. Lars or anyone know where you may be able to find any more of them?

 

[billh1289]

It seems like all those that used to make the extra capacity aux tanks have stopped...and those that offer the 11 gallon poly tank aren't as advertised. Lars or anyone know where you may be able to find any more of them?

Aero still has it listed on their site under products, but I don’t if they still sell them. It’s not on their pricing page unless I missed it. https://www.aerotanks.com/vehicles/ford.html

 

[lars]

It seems like all those that used to make the extra capacity aux tanks have stopped...and those that offer the 11 gallon poly tank aren't as advertised. Lars or anyone know where you may be able to find any more of them?

I bought my NWMP aux tank about 4 years ago, and realized not long after that I was lucky to get one, as NWMP or what ever they called themselves then, was getting out of the fuel tank business. I've heard of Aero but have not done business with them. A phone call maybe?

I'm glad I got mine. I know it's a popular delete item but for the way I use my Bronco, more is better. I have 35 gallons of tank capacity and I carry another 5 on my bumper. Helpful to feed a 408 in the middle of nowhere.

 

[PDQ]

Yeah, thanks to you both as I had just missed the NWMP business timing, and I have called Aero and they don't sell them anymore either. I was hoping Aero might still say they could make one since they have the specs and jigs already, but they did not appear to be interested in going any further with the conversation. I haven't found anything close since, and they must be like Unicorns on the used market as well.

 

[DirtDonk]

Well that sucks! I was going to have them make me one as well. I never liked any of the designs so I held off for years. Just a bit off on my timing I guess.
Or "Juuuust a bit outside..." as Bob Uecker would say.
Looks like the used ones will be popular for awhile.

Might just have to go back to doing a custom again...

Mars, don't know how long you've had the tank, or if that kind of failure is "covered" so to speak, but give us a call anyway. We can at least look it up if you don't remember, and see if it's still a manufacturer we deal with or what.
I remember the old ones with all the problems in that area because they were easy to spot. The sender was held in by about 60 (ok, it was only 6 or 7 maybe) metal straps that were screwed into the plastic. Not an overly clever design, and had the expected leaking problems. But it was easy to make I guess...
And hey, they never had a problem with the neck twisting off!

PM me some info or send some pics and questions.

Paul