exocet builders read this now

[stevieboy]

Ok guys, i wont keep this to myself as it will help every exocet owner that wants a full tank of fuel. Stuart may well have to modify any new frames by putting a cross member on the left rear corner to bolt the tank to, and lose the rear middle lug, if he see's this as a good modification to a problem for all.


Right then, turn the tank round 180 Degrees so the fuel filler is at the front drivers side. The lower bump on the tank that causes all the problems is then in the rear right corner and is clear of everything. This also gives good access to the tank drain plug. You will have to cut a small corner off the rear offside lug,...pictured.. to clear the tank.

Put 15mm spacers under each corner and bolt the tank down on all but the front filler corner, you will have memfast your own crossmember on the left corner,on the filler corner put some threaded bar about 9" long, this will be used later to clamp the filler to.

The filler will be somewhere in this position, you will lose the lug when you cut the pipe to length.

All that is needed is to cut out a section of the metal filler pipe, this is about 40mm from the the breather pipe and just below the lug pictured and rejoin with some of the rubber filler pipe, this is so you can turn the lower end to mate up with the tank filler, it also means you retain the non return valve in the pipe. You then need to buy a 90 degree bend to jointo the tank, the breather is the same, cut and rejoin to original fixing. The filler needs to stick up about 14" from the tank crossmember mount as the rear hood is 15" high internally.
You need to keep the mazda fuel filler flap and the release cable and lever, this can be mounted in the rear behind seat...iva pass...
What is then left to do is cut a hole in the top of the hood and fit the fuel flap, this will need a bit of panel beating, or if you get a good cut you can bond the original grp to the flap. Very easy to do, a small cut with a thin grinder/cutter then slide in a craft saw blade and take it out in one.


When you pull the flap release your original filler is just inside and 4" above the tank.
The void in the tank where the spare wheel used to go is now behind the passenger seat which is a great space to now lose all the spare wires in,they can be coiled up and cable tied out the way to save chopping them down. I have also measured this area and found that with a small mod to the battery tray would make it possible to fit in snug, giving more room for a storage locker behind the passenger seat.

There you go lads a full tank everytime.
Please go to page 3 for view of finished job.
Steve

[gwnwar]

Good write up and pics.. do you have finished pics yet of flap in place..

[stevieboy]

Thanks for the comments, ran out of time today due to searching everywhere for the flap, got the rest all lined up to fit, pics to follow as it progresses.

[h5ngs]

Looks interesting, one thing i never did like was the fuel filler positioning.

[John B]

damn I sold my fuel flap......
Can't wait to have a look at your progress Steve.

[samuelt]

Great advice Stevie! I am not past the point of no return on my tank and will be changing my setup on return from holiday. Thank you .

[lukiez]

drat! you beat me to it in trying to utilise the original filler flap... still i have an idea up my sleeve

altho i hadn't considered turning it around, good thinking! centre of gravity should be lower now.
i guess the profile of the flap needs to match hence the need to bend it to shape?

[stevieboy]

If you use a very fine cutting disc to start with then use a fine craft saw blade you can get the whole out in one, you then mount the flap just inside and bond the original cutout back on the flap with pu, this gives the correct profile back and all colour matched.
All this sounds hard work but its took longer to explain than to actually do the job.
Steve

[lukiez]

what exhaust are you using? having trial fitted the tank 20 mins ago, the bulge underneath hangs low so wondered how much space is there between the tank and exhaust?

naturally i was thinking of placing a heat shield there if there's space for it.

also the inlet pipe for the tank is right up in the corner so how is the pipework arranged with the filler? if you could show a picture of it "complete" as it would be under the grp if its possible

[stevieboy]

If you mount 15mm spacers as mentioned then look underneath at the exhaust hanger, this is in picture 3, there will be about 6 to 7 inches to the top of the exhaust.
Your right about it sticking up in the corner, thats where it should be, please read the thread again as i modified the post earlier, in particular the piece about lining up the filler pipe.
I think the final finish on what you see when you open the flap is down to individual choice, but it has to be better than only getting half a tank and spilling it on your foot at the same time.
Steve

[John B]

Steve, do you think it will be possible to do this with an aftermarket fuel filler?

[stevieboy]

As you you know John, there is a contour on the bubble, so its down to if your going to fit the original cutout back on to the after market flap.
If your talking about the filler pipe, then anything will do to get you into position, the main thing is turning the tank first, after that its quite simple.
The only reason i've brought this to everyones attention is that it can be done with all original mx5 parts, the only extra cost is a 90 degree bend.
Steve

[John B]

Cool, can't wait to come up and have a look. Have you moved it yet?
Keep up the good work.

[stevieboy]

Unfortunately i left my camera with my car and didn't realise till i got home, but have now done the filler pipe. The way to go is to cut the bend out of the metal pipe and rejoin with some of the original rubber pipe, you should end up with a straight pipe, then when you attach this to the rubber bend from the tank it will be somewhere near. Make a plumb line and position it where you want to make the hole on the rear panel, mark this as a centre for the flap, remove the rear panel and let the plumb line down again. This is where you need to make your final fix for the pipe, the line will give you the position and the height.
Steve

[stevieboy]

Hi Guys, has anyone tried my conversion yet? Always open to criticism and questions, but non not even from boss Stiggy, its all gone quite .