MK1 Tintop, Mk2 Engine Swop Done, Still Probs-Petrol Tank?

Hi All

Sorry Ive been a bit absent recently, this is due to us being very very busy on Evie's facelift. Things have gone slightly slower than planned, think we were a bit optimistic!

So far we have completely swapped the engine & gearbox - converting her to manual in the process. New engine is from a mk2 1.6 driver with gti cams, twin choke weber and completely rebuilt 6000m ago. All went fairly well, some mods had to be made including chopping a bit off the gearbox (?!) and new steering rack as the auto one didnt have some brackets we needed. Originally we got a cheapo rack from the scrappy but ended up taking it back and getting a new one.

The conversion from auto caused a few wiring probs due to reverse lights etc and because the auto only started in park, other bits had to be done. also had to use the old mk1 temp thingy but block a hole up!

Oooh and Evie is now the proud owner of a telefunken (remind me if I ever loose my marbles and become pregnant again, that is what im calling my third child!). Apparently telefunken makes her have electronic ignition.

She has also been lowered 40mm - after the auto box came out she was so high up at the front it was unreal - pics to follow. She has also got brembo cross drilled vented discs and green stuff pads. Ive got a few more bits to put on her - nice lights etc & my new wheels but not fitting them until after the respray.

She has a mk1 gti manifold - aparently although we think it is a cab one now!! Also new exhaust system. Along the way every cable has been replaced.

She has also got a complete change of interior (from my gx) so is now very much less blue! Also a decent stereo was put in yesterday.

Now onto the problem!! She started first time at the lock up where we mended her but on the way back she kept loosing power & then cutting out. We limped her to the petrol station, filled up and she was fine all the way home. We are not using her much at the mo until things are sorted but it does seem that below 1/2-1/4 of a tank, she has a big problem! Thinking about it, she had started to do this a week before the engine swop. We are taking an educated guess that she needs  a new filler neck & tank….Ive found a decent faq on here about the neck but is there any tips on doing the tank? What other bits do we need? It will be pretty much the only old bit on her thats not been replaced & we've had to use 2 fuel filters for a while to keep her going!

I know its prob a big horrible job but it has to be done so any simple advice would be much appreciated!!

if you have to remove tank , i would suggest spraying wd40 on the axle mount nuts now and keep spraying wd40 everyday untill you have to undo the nuts, i do this to minimise the chance of the bolts snapping, which in alot of cases they do.

Don't just spray them get them as clean as poss with a wire brush. And then wind the nuts backwards and forwards spraying WD as you go.

You will probably need to undo the brake flexi unions. It is easier to just cut them and replace them off the car. They are around a tenner each from GSF.