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.