Golf Syncro / Rallye fuel tank, MK4 fuel sender?

[3Tripnip]

I’ve searched to see if anyone else has tried this….but no luck. I was wondering if anyone has put a MK4 fuel sender in their Golf Syncro / Rallye fuel tank? I know that the FWD MK3 tank will go directly into the FWD MK2, and allows the use of the MK4 fuel sender (larger top opening). The reason I ask is because I want to use MK4 clocks in my engine swap.

My thought is to cut out the top opening from a MK3 fuel tank, then swap it into the Syncro / Rallye tank. I’ve read about using a cement / bonding product that is meant for fuel tank repairs. Anyone done this modification? Any thoughts / suggestions? Thanks!

Ben

[Chris S]

Unfortunately the mk 3 Syncro tank will NOT fit the Syncro 2

The later Passat tank opening will also fit, I welded mine in using a plastic welding set I have here and a Passat tank top, you can also make 2 metal rings and and use nuts & bolts to clamp the wider neck & flange to the old tank (with a suitable sealent inbetween of course.

[3Tripnip]

Thanks for the response. My plan was to cut out the opening from a FWD MK3, and weld it into the Golf Syncro / Rallye tank. What sort of plastic welding equipment did you use? Do you have any pics of the results? [] Thanks!

[Chris S]

http://www.welwyntoolgroup.com/plastic-welding.aspx

[vrt]

I’d like to see the end result of this hybrid.

[3Tripnip]

quote:

---

Originally posted by Chris S

http://www.welwyntoolgroup.com/plastic-welding.aspx

---

Nice, thanks for the info!

I’d also like to see pics of the hybrid. I’ll definitely post pics of mine through the process. I’ve got two Rallye tanks….hopefully at least one will turn out well.

[hiawata]

This is all that you need to do to use your original mk2 fuelsender to work with mk4 instruments:

Just solder the blue wire on the opposite side of its original place:

I have done it on my mk2 with A3 dash and instruments, more info in my project thread:
http://forums.vwvortex.com/showthread.php?4059536-My-turboed-Mk2-syncro&p=65686718&viewfull=1#post65686718

[Author]

Posts