A common issue with Grand Wagoneers is rusting gas tank skids. Gas tanks on Wagoneers are plastic. To support the weight, the gas tanks are fastened to a metal skid. Then the skid is bolted to the frame. This is a great setup as the gas tank can not rust out and clog fuel filters but Jeep made the skid plates out of thin metal with poor rust prevention so they do not last.
I disconnected the fuel lines and fill lines then dropped the tank. Skid is full of dirt and rust. The straps that hold the tank to the skid where rusted through so removing the tank from the skid was easy.
I then inspected the frame where the gas tank lives. This is also a very common area for rust to happen. This looks bad but the frame was 100% intact. There was ton of dirt build up on the frame that at first looked like rust. The rusted holes in the left side of the picture is left over parts of the skid plate that was still attached to the frame. I cleaned up the frame and painted it with some chassis saver to prevent any further rust.
Then I cleaned up what was left of the skid plate. I was hoping to repair the skid by patching it but the skid was to far gone at this point.
Then pulled the skid plate triangle brace and cleaned it up. Swiss cheese steel. I decided to rebuild the triangle brace first since it will be easier.
Built the new bracket parts for the triangle brace. I added nutserts to make install easier later.
To make the rest of the triangle brace, I traced it onto some cardboard. Then I cut out the cardboard and mocked it up with the braces I cut out steel.
Then I copied the cardboard into some 14AWG steel. The steel was bought LTP (Less Then Prime) which means it is rusted but it was inexpensive. Cut the steel out and then cleaned up with a flappy disc on the grinder.
I then tacked the brackets onto the steel and compared it to the original bracket. Looks good to me!
Triangle brace is complete. Time to start fabricating the skid plate for the gas tank.
I started measuring the skid plate and started cutting some steel.
With the skid plate and triangle bracket fabricated and painted I installed the gas tank. Before that I cleaned out the gas tank with a pressure washer and dried it out. Then the gas tank received new gas tank straps, vents, vent hoses, and sending unit.
I then installed the skid under the wagon. Fit great and now I do not have to worry about the gas tank falling out.