Dec 71 FJ40 fuel tank question

[Mattmerry8]

So I'm looking for a replacement for my gas tank that has a rusty bottom with pinhole leaks. I ordered one from Toyota for under $500, then they emailed and said they wanted another $125 for freight. I cancelled on principle.

Back to either try and repair or replace.

I'm wondering though, if I could use a new 1973 - 78 tank for under $300 instead of a 1968 - 72 for $700? ...I mean for crying out loud, there's gotta be an easy and cost effective solution.

Open to the wisdom and experience of this community! Thanks in advance!

Pics of my old tank. Link to replacement in question

Fuel / Gas Tank FJ40, FJ45 1972-1978

Fits FJ40 & FJ45 9/1972 – 12/1978 – Constructed of rugged Polyethylene for Cruiser Corps - This 12.5 gallon poly tank is designed w/ the same look and style as the OEM. Unlike Toyota's metal tank, this one will not corrode or rust. *Ships directly from manufacturer

cruisercorps.com

 

[cruisermatt]

If you don't want to pay shipping, buy a new tank from your local dealer.
the 73-78 tank is very different in terms of the filler neck angle and is also a smaller capacity. (16 gallons vs your pre-73 tanks 18 gallons)

And avoid the poly tanks. They are garbage and even smaller capacity then the OEM 73-78 tanks

 

[peesalot]

Also be aware , if your cruiser has the evap in the middle seat back you will need the tank with those vent lines in the middle as yours has. That was a specific date range that they used those and it wasnt 72' to 78'

 

[vfrer]

Try one of the online dealers that offer free shipping like serra toyota. If you can wait they have 15-25% off sales occasionally and usually during big holidays. I got 77100-60012 from serra in June shipped to MA from AL for under $350.

Tank Assembly, Fuel

 

[charliemeyer007]

Back in the 80's my tank started to weep in a seam. I bought the alcohol proof gas tank liner from JC Whitney. Still there, still leak free. Yep looks like some small holes and some thin zones to boot. Inert the tank with CO2 then use a brass wire wheel (non - sparking) to clean off the rust. There are gas tank epoxy stuff to treat the damaged area that you finish cleaning. Then do the liner thing on the inside.

My dad welded many a gas tanks. One did explode and wrap around the rafer of the hanger ceiling! I'll bet he paid more attention to the inerting process after that.

My Datsun B210 aux tank was modified by cutting off and epoxying the return inlet shut with a bolt. Tank is in bad shape now - I might weld up a new one or fix the Datsun one again. I really enjoyed have 30 gallons of fuel on tap

 

[diesellibrarian]

I am running a later tank in my 40, which is also a Dec '71 build.

The filler neck has a different angle, as has already been mentioned. I was able to make it work with a pliable new filler neck hose from City Racer. There's no way the crusty OG hose would have worked with this setup.

A couple of other notes:
- The later tanks (not sure what year mine is) has an evap manifold coming off the tank, and there's no obvious place to mount it on the '72 FJ40. My plan is to either stuff it into the back of the passenger seat, or buy longer evap lines and mount it to the passenger side quarter panel somehow.
- The later tanks have an inlet for the fuel return line that is located more or less where the send line is on the earlier tank. I plan to cap that off. The fuel send on the newer tank is underneath, and it may require some finagling to get the fuel hose to the hard line under the truck.
- Other than that, the tank drops right in like it was meant to be there.

Here are a couple of pics:

Note that I don't really know what I'm doing here, but so far it's looking like it's going to work ok.

 

[Mattmerry8]

Try one of the online dealers that offer free shipping like serra toyota. If you can wait they have 15-25% off sales occasionally and usually during big holidays. I got 77100-60012 from serra in June shipped to MA from AL for under $350.

https://autoparts.serratoyota.com/products/product/tank-assy-fuel-771006001

http://

I am running a later tank in my 40, which is also a Dec '71 build.

The filler neck has a different angle, as has already been mentioned. I was able to make it work with a pliable new filler neck hose from City Racer. There's no way the crusty OG hose would have worked with this setup.

A couple of other notes:
- The later tanks (not sure what year mine is) has an evap manifold coming off the tank, and there's no obvious place to mount it on the '72 FJ40. My plan is to either stuff it into the back of the passenger seat, or buy longer evap lines and mount it to the passenger side quarter panel somehow.
- The later tanks have an inlet for the fuel return line that is located more or less where the send line is on the earlier tank. I plan to cap that off. The fuel send on the newer tank is underneath, and it may require some finagling to get the fuel hose to the hard line under the truck.
- Other than that, the tank drops right in like it was meant to be there.

Here are a couple of pics:

View attachment 3729290

View attachment 3729291

Note that I don't really know what I'm doing here, but so far it's looking like it's going to work ok.

I am running a later tank in my 40, which is also a Dec '71 build.

The filler neck has a different angle, as has already been mentioned. I was able to make it work with a pliable new filler neck hose from City Racer. There's no way the crusty OG hose would have worked with this setup.

A couple of other notes:
- The later tanks (not sure what year mine is) has an evap manifold coming off the tank, and there's no obvious place to mount it on the '72 FJ40. My plan is to either stuff it into the back of the passenger seat, or buy longer evap lines and mount it to the passenger side quarter panel somehow.
- The later tanks have an inlet for the fuel return line that is located more or less where the send line is on the earlier tank. I plan to cap that off. The fuel send on the newer tank is underneath, and it may require some finagling to get the fuel hose to the hard line under the truck.
- Other than that, the tank drops right in like it was meant to be there.

Here are a couple of pics:

View attachment 3729290

View attachment 3729291

Note that I don't really know what I'm doing here, but so far it's looking like it's going to work ok.

I was thinking this too...a longer flexible hose from filler neck to tank...like the one you're using. Also talked to a radiator repair guy down the road. He said it might be around $150 to fix. Even if it costs more I'm still ahead of Toyota and their $200+ freight