Ex tank - fill tube installation

[muns53]

The installation instructions and pics that came with the Ex tank were spot on and the fit was great. Hopefully, these pics help supplement that and folks can see what's going on with the new filler routing. It's tight, but manageable - and eliminates the holes in the frame, etc.

First, to get a sense of where things go, it really helps to lay out the filler tube in entirety to see which parts go in sequence. Second, measure where the filler neck on the tank sits in relation to the nearest mounting tab. (Mine was 5 1/2 inches in to the middle from the outside edge of the tank and 7 inches higher than the top edge of the tab.) Then, you can take the last filler pipe piece and trial-fit it over the brace in the spot where it will live by measuring up and in from where the brace will hit the frame member. Then, you can follow the pipe back to the fender well and check that the spot you think you want to drill is actually the spot where you should drill. (Measure thrice, cut once, eh?).

PS - A dremel tool is real handy for cutting into the bracing just past the fender well if that's where yours ends up lining up - you can see the cut in the pic called "hole#3" (for the third hole you'll have to drill) that I had to do.

[fiveohpatrol]

I guess I'm having a hard time picturing where the tube is ran. Is it up and over the frame rail? Are the excursion kits coming like this now, or is this just a modification you made? If so, that's a good improvement. I really didn't enjoy having to cut a hole in my frame.

[muns53]

Yes - up and over the frame rail - this is the way it came from DFA. The fill port is up on top of the tank - I think it used to be on the side.

[2000XLIFTED]

Yes - up and over the frame rail - this is the way it came from DFA. The fill port is up on top of the tank - I think it used to be on the side.

That is correct, This new fill goes through the inner fender well much higher than before and just clears the top of the frame rail then takes a 90 bend down into the top of the tank. This is even better than what I did by moving fill to the back of the tank. Its a much shorter and direct run, plus you can probably fill it up better when on a slope since the fill is in the roof of the tank now. I like it, worked out pretty good!