Building a fueltank from scratch - Mailtruck T5 Project

🛠️ Project T5 Mailtruck | Fuel Tank, Firewall, Customer Builds & A New Video Format! 🎬

Welcome back to Bad Decision Works! In this shorter-format episode, I’m trying something new—quicker weekly updates with all the essentials from the workshop, and separate videos for deep dives like fabrication tutorials and interviews. Let me know what you think of this new format! 👇

This week:
✅ New aluminum fuel tank is designed, welded & leak tested
✅ Removable driveshaft tunnel replaces the old one
✅ Glass fibre firewall deleted – space cleared for electronics
✅ Generic motorcycle mirrors installed (plus a 3rd for safety!)
✅ Front wheels modified to fit Volvo hubs
✅ Frame jig sold to a new builder in Borlänge
✅ First customer cars rolling in!
  🔹 BTCC-style Volvo 850 roll cage build
  🔹 KP61 Starlet: cooling upgrades + relocated fuel filler
  🔹 AE86: Exhaust tip cleanup & exhaust polishing

This new video format means faster uploads and a more sustainable workflow—especially now that customer builds are becoming a big part of the shop!

🛒 Support the build – grab some merch: http://www.baddecision.works
📆 Catch me at Elmia in the Vertygsboden booth!
🔪 Check out my partner Scandcut: http://www.scandcut.se
🔔 Like & subscribe for weekly updates and chaos!

📖 Chapters
00:00 Intro
00:21 New video format – why shorter?
01:56 Frame jig leaves the shop
02:46 Removing original firewall
03:36 Driveshaft tunnel upgrade
04:13 New Fueltank!
07:28 New wheels and center bore fix
06:46 Mirrors
09:28 Customer builds: BTCC Volvo 850
10:49 KP61 Starlet – cooling & fuel cap mods
12:47 AE86 exhaust tip finish
14:33 Wrap-up & Elmia teaser

🔧 Hashtags
#ProjectT5Mailtruck #VolvoT5 #Elmia2025 #DIYRaceCar #DragAndDrive #BadDecisionWorks #HomebuiltRaceCar #TurboVolvo #WeldingLife #FabricationLife