Fuel Tank Design with In-Tank Pump

[MarkODonnell]

DESIGN FOR REPLACEMENT FUEL TANK

I had a custom tank made by a local specialist (SP Sheet Metal Company/ http://www.sptanks.com / 446 North Main St. Barnegat, NJ 08005 / phone: 609-698-8800). I provided the attached design and they manufactured the part. They added internal baffles (which is why I added some details about the internal pump (with its filter sock) and fuel gauge sender for my project. They constructed the tank from 1/8” thick marine grade aluminum. I also had it powder coated afterward.

I used an internal fuel pump from FITech (part # and instructions are in the second attached document). The standard FITech product only works with tanks of a limited depth. They sell an extension to allow it to function with deeper tanks (which I purchased and used). Unfortunately, the extension kit does not include an extended wiring harness to get power to the pump, which sits at the bottom of the tank. As such, I needed to cut the standard harness and solder in addition wires to length. I was concerned about having wire joints inside my fuel tank. As such, I staggered the splice points on the two wires to reduce any likely short (and related spark). I also wrapped the splices in a fuel hose and filled the hose with putty that comes with a fuel tank repair kit. So far… no kaboom sound.

I hope this is helpful.

[MarkODonnell]

Sorry... the file size is 579 KB. This forum does not allow users to post files of this size. Send me an e-mail if you need the design diagram (mark.odonnell@comcast.net).

[Nomad]

Do you have any pictures Mark? Sounds interesting. How much did it set you back?

- Damon

[MarkODonnell]

Before you asked, I never calculated the total price tag. Now that I have... I'd say I spent too much. We do stupid things in the name of love. Here's the break-down: $575 for the custom tank; $30 for powder coating; $350 for the in-tank pump + $10 for the deep tank extension (https://hyperfuelsystems.com/products/40019/); $107 for a 15" tube-style fuel sender (https://shop.classicinstruments.com/sn38t); $35 for an inline fuel filter; and another $150-ish for braided fuel lines and AN fittings.

It can deliver enough juice for an 800hp LS engine. I'll make that swap once I hit lottery.

I have detailed design diagrams for the tank, but the M715 ZOne site will not let me upload them (too large). I'll reply with the document if you send an e-mail (mark.odonnell@comcast.net).

[MarkODonnell]

I just figured out how to share the design... uploaded five pictures (one per page). Enjoy.

[ray steadward]

I just figured out how to share the design... uploaded five pictures (one per page). Enjoy.

Thanks Mark! Designed to fit in the stock location exactly? How did that work out? I was thinking of enlarging one to carry some more fuel for said 800HP LS.....

[MarkODonnell]

The tank design I posted will occupy the same space as the original. The same straps are reused to secure this tank to the chassis. It holds approximately the same amount of fuel as the original.

The only difference you will see... the top does not include radius/rounded corners. It cost more to add the radius and they serve no purpose on the top side of the tank. The radius is on the bottom corners to allow for reuse of the original tank straps.

Jealous you did an LS swap.

[ray steadward]

Ohhhh.......It's not done.....just picked up a boatload of stuff from the sandblaster yesterday