I have some pin holes in my tank, and I was wondering if any of you guys have switched out the tanks of a similar vehicle, or if you have some other ideas besides the tank coatings, mine is pretty brittle. I have a 1986 1st Generation SWB Montero....I need some ideas, I'd rather go with a poly tank! I am also open to the idea of making a poly tank off something similar work... Let me know what you guys would try.
Thanks

I see from your profile your rig is an 86. It's important to include that in your post because there are very distinct differences between the 2.6L engine in yours and the 3.0L models including the fuel system. The 2.6L has a different size/shape gas tank than the 3.0L model.

I don't believe any poly tanks are made for Montero's. You may be able to find one that fits though which would mean fabricating straps or supports to hold it in place. Alternatively you can find plenty of fuel tanks in good condition at salvage yards around the country. My 89's tank for example is completely rust free.

I recommend for an easy fix searching on car-part.com for one in a South western state that doesn't get much snow.
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Easy process. I did it three years ago when the original tank developed holes. I did it flat on my back on the grass. As I recall you just have to undo some straps, maybe a skid plate, pull the fill tube, and disconnect some smaller things as you drop the tank. There will be some small things you must transfer from the old to the new tank. It's all pretty obvious once you start. I'll add a picture of the tank if I can.

I didn't have to worry about draining the tank, as you can see in the picture. The hole is by the far strap.

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X2 on what off-roader said. I have one, but I'm not parting with it, I have my eye on a Montero that has apparently been to close to the ocean and has developed some pin holes. But I have seen a couple in the JY's , so they can be found.

I have a spare, but other side of the country.

You sold me that replacement tank. I drove up to Placerville to pick it up. I shipped it to Maine for installation. The Montero is still there. It lives on an island, so it's always salty.

I put a 20 gallon YJ Jeep tank in my friend's '86 SWB 4 cylinder. I had to make a new skid plate (1/4" thick bottom, 10 guage sides) and make a new filler hose and hose size adapter to connect to the stock filler neck. A '95 ZJ Jeep sender on the YJ fuel pickup module (with an added resistor) operates the stock gas gauge perfectly.

The stock tank was smashed down to about 12 gallon capacity, the factory tank costs aroung $500 if I remember right. I think I had around $40 in the steel to make the skid, (twelve years ago or so when I did it) the tank came free from a YJ that got a 26 gallon Aero tank. It's taken many heavy hits and only has a few scratches in the skid plate. You can lift the rear of the loaded Montero with a floor jack under the tank! It sits about 1" lower than the factory tank and fits pretty well between the leaf springs. I had to modify the tail pipe to route it to come out the side behind the tire and cut off the original fuel tank mounts on the frame and make my own mounts from 2" square tubing to get it to fit.

My buddy is bringing his Montero over this weekend or the next for me to change the CV boots and rebush the idler arm. I'll try to take a picture of the Wrangler tank installation.

I have another. <img src="/forums/images/graemlins/smile.gif" alt="" />