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The hardest part was getting the seal bracket correct on 3 axis. I finally decided to reference the seatbelt hole, then using some parallel guides and a level, get it as close as I could.
It worked since it fit like factory. Getting it wrong meant the seat wouldn't slide or would be tilted.
I took some time out to weld on a new exhaust pipe behind the axle beam. W386 chose the turndown at the end, which should also serve as a venturi like on the new trucks.
And then on to the next problem, which W386 tackled while I was working on the rust work.
Here was the problem, which happened on my and W386's B4V's about a month apart. We've both had ratchet straps in place of the broken fuel tank straps as a temporary measure. W386 went to Blue Water Marine locally and had them make up some fuel tank straps from some marginal ones I picked up in the local junkyard. I did not have any for a wagon but still own a sedan (along with 5 others locally I work on). Upon measuring them I found one of the straps is the same and the other two are exactly 4" longer than the sedan straps. Blue Water made them from stainless steel so they'll never rust again and they were $100 for all 3, which was a good deal since the one strap that is available from the dealership is $55 and still carbon steel.
The wagon straps are on the left, the sedan straps on the right.
The only thing missing and that required modification was the ends, some of which needed to look like this at one end. Easy enough to do with an angle grinder.
W386 had a great idea on replacing the straps while keeping the fuel tank in place.
I doubted the bolts holding the straps would come out but he worked with them over 2 days and they relented. He used some of my Kroil and now absolutely swears by it. He said anything less and they would not have come out. I'll pick up a few more cans since I also find it indispensable.
Not a lot of room underneath.
And the finished product. Due to the incompatible nature of stainless and carbon steel, he used some plastic sheeting as a barrier between the two surfaces and added some bicycle inner tubes as cushioning for the straps. Once the tank has settled onto the straps for some time the outer layer will be cut away since it'll just hold debris anyway.
W386 just came back with my wagon, which passed inspection just fine. They did the alignment but said the AC system has a hole in the condensor, so I need a new one to get it working again. I'll investigate that later when I can move around better.
And I just realized I'm coming up on another timing belt and I also need to do one on revkev's B4. He volunteered to do a timing belt on an A4 in exchange for using a backhoe around his place so I'll give him a hand or knock that out as well, but his garage needs to be finished first (it burned down earlier this year).
