HI Neil,
I think you said you are using the larger metal filler neck and matching
tank.

If the problem is the filler neck won't fit nicely through the frame hole..
what I would do is get the later type tank with the smaller filler neck
hole,
and the smaller plastic filler neck.
Those are far, far easier to remove and install at the gas cap end too,
compared to the metal type.
like 8 times easier.
I always use the small filler neck tank if I can.

I don't like the idea of grinding on a gasoline fuel tank,
but I think banging away on it, like with a big rubber mallet is
'appropriate ...lol !

Stay cozy !
Scott
www.turbovans.com
----- Original Message -----
From: "neil n" <musomuso@GMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, December 28, 2010 5:16 PM
Subject: Gas Tank Fitment; Subframe Crooked?

> I'm sorry for all these posts. Just wanted to keep them separate in
> case it helps out others.
>
> The tank that c/w my Westy, and the new tank, fit poorly. (filler
> opening doesn't line up). As per my other post, moving the squished
> EVAP hose made no difference.
>
> Body repair work (PO accident) was done at one point. Receipt shows
> most of repair time went to:
>
> "repair to LF hinge pillar" and "R&R LF door".
>
> How badly does a Vanagon have to be hit before it causes the frame to
> be misaligned? I'm thinking the frame or body was bent enough to keep
> tank from seating completely. Lip of tank rubs (left a mark) on driver
> side of forward subframe.
>
> Is grinding down the edge of the tank a bad idea? Tank has ~ 1/4" of
> metal I could play with before getting to the actual seam.
>
> Anyone had to do this? Is this a bad idea? Can't see where else it
> might be hanging up.
>
> I'd pop in a filler pipe adaptor but my Visa card is cut up (fraud),
> and I really don't want to wait around for cheques to clear, parts
> shipping so....
>
> Mucho thanks,
>
> Neil.
>
> --
> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>
> http://tubaneil.googlepages.com/
>
> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines