In this episode, Classic Car Restoration host Mark Lambert continues with work on the platform and chassis of the 1962 Corvette -- including removal and replacement of the fuel tank, servicing the brakes, replacing the exhaust system and checking the wheels and tires.
Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgraded kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select. Saftety Alert: When working on fuel tanks or around gasoline or other flammables, avoid using incandescent work lights, such as the familiar swag or hanging lights on the end of a cord. If a lit incandescent bulb should be dropped or otherwise broken, it could ignite gasoline fumes and cause an explosion. Use florescent work lights when working around gas or fumes. Also, work in a well-ventilated area. Safety Alert: Always wear eye protection when working with power tools or pneumatic tools.
Fuel-Tank Replacement
In an earlier segment, the fuel tank was removed from the Corvette to prevent fire hazard while welding, grinding and torch-cutting was being done on the metal frame of the vehicle, a process which causes sparks and could easily ignite gasoline or gas fumes. The fuel tank was found to be worn and damaged. Following are the steps in the removal of the fuel tank, and its replacement with a new one.
Materials:
Standard automotive tools (socket-wrenches, screwdrivers, etc.)
Power wrench
Locking needle-nose pliers
Replacement fuel-tank, sending unit and pickup hose
Fuel-tank pads
Auto-body seam sealer
Spray adhesive
Eye protection
Steps:
- Mark Lambert and restoration specialist Roger Schmidt prepare to remove the fuel tank from the vehicle. The battery is disconnected to eliminate the chance of a spark igniting gas fumes during the procedure. On the Corvette, the fuel tank is located beneath a hinged lid behind the seats and passenger compartment (figure A) instead of the more typical location underneath the car.
- Raise the lid, fold the seats forward and remove the protective mat that covers the gas-tank and shroud.
- With the mat out of the way, remove the gas-tank shroud (figure B) and set it aside. Keep the screws in a labeled zip-lock bag to avoid losing them.
- Remove the fuel line by first clamping the line with locking needle-nose pliers to prevent fuel leakage, then pulling the line off of its connector. (In our case, the fuel line was rotted and brittle, and broke when it was removed. It will be replaced with a new line during re-assembly.) Also remove the gas-tank breather line (figure C).
- Use a socket wrench and extender to unbolt and loosen the fuel-tank straps (figure D) on both sides of the tank.
- Loosen and disconnect the electrical wires connected to the tank. In our case, we found the ground wire to be broken (figure E), explaining why the fuel gauge had not been functioning on the vehicle.
- Loosen the clamp on the fuel-filler neck, and detach the tank from the neck.
- With the clamp and straps both loosened, and the wiring disconnected, the fuel-tank can be carefully maneuvered and lifted out of its compartment (figure F).
- Unclamp the fuel lines and drain any remaining gas into a bucket container.
- Important: Gasoline, antifreeze, motor oils and other automotive fluids are toxic and constitute environmental hazards. Always dispose of spent automotive fuels responsibly.
- With the tank removed from the vehicle, it can be set on a worktable and inspected for wear and damage. In our case, the tank was in poor condition. Signs of corrosion were evident, and there were patches from previous repairs to the tank (figure G).
- The fuel filter was found to be split (figure H), allowing sediment to run up through the line. The pick-up line was completely split making it essentially ineffective. The latter probably explains why a previous owner had installed an electric fuel-pump on the vehicle. It was determined that a new fuel tank, sending unit and pick-up hose were needed.
- Clean out the gas-tank well, and install new gas-tank pads using spray adhesive (figure I).
- Carefully position the new tank into the well, setting the filler-neck in first, and maneuvering the tank so that it sits securely in the well (figure J).
- Secure the tank in position using the gas-tank straps.
- Attach the ground wire to the sending unit to ground the circuit. (In our case, the damaged ground wire had to be repaired first.) Then, attach the live connection to the top of the sending unit, completing the circuit (figure K). The sending unit works in conjunction with the fuel gauge to provide a read-out for the amount of fuel in the tank.
- Attach the fuel line, securing it with the line clip to the pickup tube on the new tank (figure L).
- Once the fuel line is connected, attach the breather hose to the new tank also (figure M). The breather hose allows displaced air to escape as the tank is filled with gasoline.
- Re-insert the fuel-filler hose and attach it to the new tank (figure N), securing it with a hose clamp.
- Before installing the gas-tank shroud, caulk around the tank using body seam-sealer (figure O). This will help keep gas fumes out of the passenger compartment.
- Replace the gas-tank shroud (figure P), and secure it with the screws that were removed earlier.
- Replace the protective pad to complete the installation.
- Replace the gas cap with a new one.
In the segment that follows, the brakes are serviced on the Corvette.
RESOURCES :
Corvette Black Book : 1953-2001
Model: 0933534477
Author: Michael Antonick
Corvette: The American Legend
Model: 0785343741
Author: Consumer Guide Editors
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
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