Mitsubishi Projects: Gen I Fuel tank Armour Short Cuts
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Author/Photographer:Don Huysmans | Editor: Phil Hansford
November 24, 2001

Fuel tank protection for 1987 2-dr 2.6L with 60L/12gal tank

This was the deciding factor for new tank armour - the Rubicon left its mark!

Editor's Note: This project was completed on a 1987 Mitsubishi Pajero, "GenI" 2 door, with 4 cylinder motor, and 16 gallon fuel tank. Whenever doing work near the fuel tank, be sure to have adequate ventilation, and fire extinuishers close by, in the event of a mishap.


This tank protector is intended to replace the existing skidplate. To remove the old cover, unfasten two bolts at the back, closest the rear bumper, and two at the front, closest the rear axle. These bolts are smaller than the 4 tank support nuts.

The new tank gets some needed support

To install the new protector, prop up the fuel tank by supporting it on either side, up against the tank flange where it's closest to the wheels. Remove the 2 nuts on the back and front of the tank carefully, and see if the tank stays in place. These 4 nuts are all that holds the tank to the truck. Place the new protector on the tank support bolts, and replace the 4 nuts. No washers are needed between the protector and the tank at the front. Use the existing washers from the back bolts as a spacer between the tank and the protector at the back bolts.

This diagram gives the measurements for both the iron and the plating

Cut the checker plate into 5 pieces, numbered as per the diagram:

Cut the angle iron into 3 pieces:

Assemble the 5 checker-plate parts on a frame, or jig, with measurements taken from the diagram, which shows the outside perimeter of the jig, or the inside perimeter on the new tank cover.

02-				rawmaterials.jpg 03-welded.jpg 04-painted.jpg
The raw materials The armour looks very tough This paint will look better on the rocks

The 9" angle iron is centered on the back edge, while the 4.5" pieces are spaced with 11.5" between them on the back edge, as shown on the diagram. The raw materials image includes a piece of plywood marked with the bolt pattern for the tank.

06-installed.jpg 07-testing.jpg tank_bumper.jpg
Judging by that stance, this tank is ready for battle More than just a pretty face, it can bear the weight of the truck! Coupled with his new bumper, Don's worries about dragging his tank on the trails are over!

The outer seams were tacked, and full-length arc-welded with E7018 1/8" rod at 110 amps, and the inner seams were stitched with wider welds. Cleaned, primed, painted, mounted and tested!

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