I Fixed the Worst Dune Buggy Fuel Tank Design I've Ever Seen

On this episode, Brandon at Be Aircooled tackles one of the biggest engineering flaws on this Meyers Manx-style dune buggy: a fuel tank that was never designed to work with the chassis it was installed in. What started as a temporary fuel leak repair quickly revealed a much larger problem. The original fuel tank had been heavily hammered and modified just to clear the frame and steering components, leaving the fuel outlet in the wrong location, preventing the tank from draining completely, and creating constant clearance issues. Rather than patching it yet again, Brandon tears the front of the buggy apart and engineers a permanent solution. Using a brand-new steel fuel tank as a starting point, the bottom of the tank is cut, reshaped, and welded to create proper chassis clearance while relocating the fuel outlet to the true lowest point of the tank. Every modification is carefully planned around the buggy's frame geometry, steering linkage, and suspension movement to create a fuel system that actually functions the way it should. The project doesn't stop there. A completely custom fuel filler neck is fabricated from aluminum tubing, TIG welded together, fitted to the original body opening, and designed with proper venting to eliminate the problems created by the previous installation. Along the way Brandon shares fabrication techniques, welding tips, layout methods, smoke testing, mock-up procedures, and the engineering decisions that transformed a poorly designed fuel system into one built for years of reliable driving. After final assembly, the dune buggy heads out on the road for the ultimate test to prove the new custom fuel tank performs exactly as intended. Whether you're building a VW-based dune buggy, restoring a Meyers Manx-style buggy, fabricating a custom fuel tank, learning aluminum welding techniques, or simply enjoy watching thoughtful automotive engineering solve real-world problems, this episode is packed with fabrication, problem-solving, and plenty of air-cooled Volkswagen goodness. Be sure to SUBSCRIBE 🔔 so you don't miss what's next! Thanks for watching! If you'd like to show your support and look great in your brand new dune buggy (best decision of your life... thank me later), crawling around under your VW, or fabricating your own custom projects in the garage, check out the Be Aircooled web store where you'll find tees, hats, and all the merch:https://be-aircooled.myshopify.com Watch more FIXED IT episodes here:   • I Fixed It!   Get your fill of "How-To" videos here:   • Entertaining How To's   #DuneBuggy #Volkswagen #MeyersManx #AirCooledVW #Fabrication