Gas Tank Modifications

                And how NOT to have to do 'em!

These days, it's not uncommon to find the high pressure electric fuel pump is mounted right inside the gas tank of today's mass produced automobiles.     That's done  for two, well maybe three reasons. The gasoline cools the pump. The liquid and metal of the tank quiet the pump, and it simplifies system plumbing design.     Another point to consider, is the need for a fuel return line fitting and line coming back from the engine compartment fuel pressure regulator.    Yes, you could hack up a Spitfire gas tank to accept a custom made sender unit with pump attached.  Or... you could modify a standard gas level sensor unit, with a couple of feed-throughs. Attach a pump to it and lower it into the tank. That still leaves you needing to machine a second port for the return line. Technically you 'could'... use the vapor return line if you drill a hole through your gas cap to vent the tank. But that opens up an environmental issue, as well as a visible gas fume 'vapor volcano' on warm days with the car parked.      You also need to consider baffles around the fuel pickup. Sloshing of the fuel on hard cornering can lead to air ingestion by the high pressure F.I. pump. This can cause catastrophic damage to the pump as well as create dangerous hesitations as the system pumps air bubbles to the injectors rather than fuel.    Let's see what we can come up with here that would let us still return everything to stock....not have to weld on the gas tank, and the average D-I-Y mechanic can do it safely and cleanly....   hhmmm....

a work in process... ...still being edited

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