I'm putting in a restored gas tank so I've currently got the existing one out of the car. What should I be looking to replace/repair while the tank is out? There is the dreaded smell of fuel if filling the tank more than 1/2 full. Is that something that can be addressed now?

Any suggestions are welcome.

Inspect vent and return lines to the condensation chamber above rear wheel. Replace as needed.

Address any rust above/near tank area.

Replace all fuel hoses and vent lines and be sure to seal all pass though locations. Exhaust fumes will seep into any tiny gaps, so find and fix them all when the tank is out. The fuel vent hose grommets always dry up over time, so that's a good place to start.

Since your Z is almost 40 years old, take a look at the flexible filler neck the runs between the gas cap and the tank. Easy to replace now.

Dennis

Inspect, refurbish or replace your fuel sending unit and the rubber O-ring that goes with it. Some of the larger fuel rated replacement hose can be found at a tractor related dealer. An old inner tube will make some nice new rubber tank straps if yours are mia or fubar.

Bonzi Lon

Do the sending unit before you put the tank back in. That damm O-ring can be tricky to get right once the tank is in and it might leak. Fill the tank with a 5 gallon fuel jug that way you can check for leaks at home before you fill it up at a station and find out you have a leak and you have to drive it home.

There is a square piece of sheet metal that is against the rear body panel. Make sure it's sealed really well as this indirectly leads into the cabin.

This would be the optimal time to do the smoke test. http://www.classiczcars.com/forums/showthread.php?31739-Exhaust-fumes-in-cabin-solved!!!&highlight=smoke+test