Bryan's RCR40

Chet Zerlin

What the chassis looks like "as delivered". Is the front of the chassis already cut out for the fuel tanks? Honestly I'm just trying to figure out as much as possible in advance of getting mine in my any pictures you want to post would be great.
The fuel tank cut-outs are partially cut out including the corners. All you need to do is "connect the dots". Not sure why they do it this way. Finishing plates are included for you to cover the holes once the tanks are installed.

I am going to leave the chassis aluminum but to what extent I polish mine is still tbd.


I now have most everything removed from the car except for the engine. I will do some fitting of alternator, compressor, and pulleys before removing the engine.

I decided to start on the fuel tanks since the front suspension is out. Here is the rough cut hole:

Happily there are no obstructions inside so this job is much easier than the retrofit like Chuck and Ryan did.

Here is the finished hole:

The right side tank slid in easily but the left side one didn't so I had to enlarge the hole..

The tank goes in this far:

Here the filler is aligned with the filler hole:



So there will be about an inch of extra space at the rear.

Here is a comparison of the cut out piece to the RCR-supplied closeout panels:
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How do the tanks mount and secure?
I'm going to fashion appropriately-sized rubber blocks on all sides to hold them in place. The end blocks can be attached to the tanks and the side, top, and bottom ones attached to the chassis. At least that's my tentative plan. I will post here whatever I end up doing.
Laid out the position of the tank trying to decide how to get the hoses and wires through.
1: stringer
2: rear edge of tank
3: fuel pickup
4: vent

Spent a long time getting the firewall and roll bar positioned:

I've reconsidered how to mount the tanks and am thinking about making brackets for them.
It took me a long time to come up with a fuel tank mounting plan that I liked and finally I decided to make some brackets.

Twelve steel rectangles, 1.5 x 2 x 1/8" and eight square tubes, 3/4 x 3/4 x .090", ready to weld:

Welded and painted, four unique brackets:

I measured carefully and drilled two holes up from the bottom of the pontoons front and rear. Then I attached the brackets to the tanks with tape and slid the tanks into their proper places. Marked through the holes to the brackets and then removed and drilled the brackets.

I made them big enough for thin rubber spacers between the brackets and the tanks.

Rear bracket installed:

Front bracket installed:

By the way, when designing the brackets I wanted to know how much the tanks would weigh so by measurement I calculated their volume at about 11.9 gallons which is about 75 pounds of fuel plus the weight of the tanks (which I forget).
I've been working on many things but my main goal is to finish the fuel tank install. With filler hoses, supply hoses, pickups, vents, gauge senders, and mounting brackets, it's a lot to do.

The supplied senders were too tall to fit into the tank so I exchanged them for shorter ones.

I pressure tested the tanks and they were both leak-free.
CVF Racing crank pulley, water pump pulley, and alternator bracket
One-wire alternator, 100 amp, with CVF fan and pulley
RCR upper A/C compressor bracket
Southwest Performance Parts lower compressor bracket
Gates 7375 water pump / alternator belt
Gates 7330 compressor belt (later swapped for 7325)

Installed evaporator -- I made sure it can be removed after the dash is installed.

Still working on the fuel tanks. I couldn't find suitable fuel pickups so I made some from stainless pipe fittings. The upper parts (on the right) will be installed after the tanks are in place.

I did find perfect 1/2" NPT vent valves.
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hi, great build so far
I take that your have ordered the "deluxe kit" from my understanding, this kit comes pre-assembled as a roller.
was it necessary to remove everything again ?