My Official OM617 Toyota Pickup Repower Thread

[OM617YOTA]

Hah! My girlfriend(strawberry blonde or light brown depending on the light) called it a reverse breathalyzer.

Today's work was the fuel filler neck. Stock gasoline fuel filler has a restrictor plate and a spring loaded flap covering the smaller hole in the restrictor plate. A diesel nozzle won't fit through it. Up until now, I'd been using a transmission funnel or holding the flap open with a stick/tube/my pocket knife and slowly drizzling the diesel in. Both ways are slow and messy. Today I pulled the filler neck, drilled out the spot welds, pushed out the restrictor plate, sealed up the holes, and reinstalled. It's now a straight shot all the way and you can see straight into the fuel tank. Note that I live in a good neighborhood, work in a good neighborhood, have a locking fuel door(for whatever good that is) and would LOVE to see someone siphon fuel out of my "gas" truck and put it in their car.

I forgot to grab a "before" photo.

1. Spot welds drilled out.

2. I was going to tack weld shut the holes. The welder was buried, I am lazy, and more importantly, the welder plugs into dryer plug and my a fore mentioned girlfriend was doing laundry. Plan Bravo was soldering some tin over the holes. Didn't go as planned. What you see here is plan Charlie. Pieces of fuel line cut and slit to form a square patch, and hose clamped over the holes.

3. Different view of #2.

4. "After" photo, all clear, lots of room for a diesel nozzle.

5. Mounted back in truck. For any flashlight folks, that is a Zebralight H51.

[Stretch]

I guess you not only live in a nice area but in an area where it doesn't rain (And that the tumble dryer is just used to fluff stuff up and make it small nice)?

I take it there's no cap at all on the tank now then?

Not a good idea if that's the case => dirt ingress - water ingress (rain)

You used to be able to get universal filler caps - along with those universal emergency fit any alternator utility belts...

...I haven't seen them for years though...

...if you haven't got one I think you need a cap. On a warm day you'll get a lot of nasty diesel smells at the very least.

[OM617YOTA]

The stock twisty fuel cap still works and seals fine, I just didn't have it in place for the pics. Running without a fuel cap was never even considered as an option, for all the reasons you stated.

I'm in Oregon in the USA. We know a bit about rain.

[Stretch]

Originally Posted by OM617YOTA

The stock twisty fuel cap still works and seals fine, I just didn't have it in place for the pics.

Oh cool

[OM617YOTA]

Ordered the Delco 22SI. Fingers crossed!

[mach4]

Wow, that's a ton of work.

When I did the same thing on my 380SL conversion, it just required drilling out a couple of plastic rivets holding the plastic flapper piece in place. It still has the metal cross piece in the neck. I was going to cut that out until I realized that's exactly the same configuration as the 300D's tank...and it's enough room to use the big diesel pump nozzles if necessary though most of the time I fill up at auto/light truck pump islands.



Looks like your solution will work just fine, but I think I'd have cut some sheet metal, formed it and used JB weld.

[OM617YOTA]

Yeah it was a pain, only took about an hour though.

[Simpler=Better]

How do you like the zebralight? My current headlamp is a hackjob mini maglite + led dropin +headband.

For the filler neck, remember: A temporary repair is permanent until it breaks

[JB3]

Originally Posted by OM617YOTA

Yeah it was a pain, only took about an hour though.

got you both beat.

my fill solution was to bore out the flapper valve with a hole saw.

[OM617YOTA]

Love the Zebralight! It's my EDC. 0.4 lumens for a week, or 200 lumens for 40 minutes, and a handwarmer to boot!

I considered a die grinder, just didn't want to knock all that junk down into my fuel tank. Hole saw would have been nice!

[OM617YOTA]

Filled up again last night, modified fuel filler does great. No leaks, no mess, no transmission funnel.

[Stretch]

Originally Posted by OM617YOTA

... No leaks, no mess, no transmission funnel.

Oh where have all the good times gone?

You are destroying what is known as "character"!

[OM617YOTA]

Oh believe me, it's still got PLENTY of "character"!

[OM617YOTA]

Just a plug for Eric at Northwest Fluid Power and Machining. He built my power steering hoses and was awesome to work with. If you're in the Salem area and need hydraulic, machining, or Fab work done, give him a call.

Northwest Fluid Power and Machining
5243 Silverton Rd NE
Salem, Oregon 97305

Email: Sales@nwfpm.com
Phone: (503) 589-9522
Website: Coming Soon - Future home of something quite cool

[OM617YOTA]

Big weekend planned. The Delco 22SI is here, and I have the stuff to build a vacuum reservoir, two if needed, in addition to the key shutoff if I can find a solenoid valve around here that's normally open.

Couple pics of the alternator. By golly that's a beast of a charging system. Also a pic of the bed of the truck full of wood chips, much dampened by the rain. New engine didn't even notice the extra weight. I barely got it all unloaded before Mother Nature cleared both barrels at once. Lots of thunder and lighting in my part of Oregon yesterday.