Ford E-Series van custom fuel tank

One of the items when you do a 4x4 conversion on the E-series platform is tackling the fuel tank.

There is only a few choices for dealing with this.

You can use the factory style tank and cut the front nose off and install an end plate.

Which works just fine but you do loose some capacity and these vans don’t get the best fuel mileage especially after converting them to 4x4.

That leaves you with the next option, full custom fuel tank with added capacity.

Check out some of the features below of our custom tanks.

Ford E-series Tank basic features

Built from 1/8th 5052 aluminum. Standard Thickness

Fully tig welding construction

Diesel heater outlet fitting added on 7.3 and 6.0 applications.

Size can be customized to fit your needs.

(Most tanks do require custom pump replacement) or modifications to fuel strainer assembly.

Billet aluminum fuel pump flange

For the lock ring style fuel pump assembly used on the vans after 2009. This replaces the use of the lock ring and uses a billet flange with factory o-ring seal and aluminum hold down.

Prototype rendering of the custom rear mounted fuel tank.

Midship fuel tank production version

Adventure Van Conversions & Accessories

  • Outfitting any van

  • 4x4 conversions on ford E series vans

  • Ladders

  • Paddle/Surf board racks

  • Bicycle racks

  • Custom roof racks

  • Custom water tanks

  • Custom fuel tanks

  • Custom shower enclosers and shower pans

Adventure Van Mechanical work

  • Lift kits

  • Suspension Components

  • Brakes

Adventure Van Electrical Work

  • Lights

  • Wiring

  • Switches

  • Stand alone battery systems

  • Solar systems

  • 12V A/C Systems

Billet aluminum fuel pump flange

The 6 bolt style fuel pump assembly used on the gas and diesel applications prior to 2009.

Billet aluminum fuel tank vent flange

The factory ford tank vent or Evap system goes right back in use with major modifications to line set.

Van Electrical panel

120V and 12V breaker system

Wabasto Diesel Heater Control

Cruise and Comfort 12V A/C control

Victron Bluetooth battery Monitor

Ford E-series Vans

The E-Series van is my favorite setup out there right now. Due to there long production run and rugged design they are easy to maintain and find parts for.

However, Ford never made a production 4x4 van, that is where aftermarket company’s come in to support that need.

Hanco Fab shop van basic details

Van: 2002 E350 Extended Body

Engine: 7.3 Diesel

Transmission: 4R100 with billet converter with a Np273 transfer case

Front axle: 2006 F250 with 4:10 gears, Custom Brackets for radius arms and Bilstein 5100 shocks

Rear Axle: 2008 F250 with 4:10 gears, held up with Pro-comp 4’’ lift springs for 08 F250.

Fuel Tank: Custom 48 gallon diesel tank built in house.