It looks like I need to mod (weld) my fuel tank to take the Mr2 pump and sender. Does anyone have any suggestions on how to do this safely?

Am I going to need to put a swirl/catch pot in there as well or will I get away without?

If only possible, dont do it as it is risky (been there done that...)!

If it is a must, was it over with diesel oil (can keep the oil in it for a couple of days). Fill it with water, open the filler and work carefully.

The two systems that you can use Phil are the same for turbos and fuel injection. You can either use a high pressure pump from the tank (which would need to be gravity fed, OR you can use a low pressure pump to the swirl pot and a high pressure pump from that.

If you can mount the pump successfully in the tank, then you will only need a feed and return from the pressure rail on the engine, which would be the most simple design.

I think we should sort out a design for a ali fuel tank, with a production car high pressure pump mounted in it. There has got to be a (small) need for it.

I think swirl pot was the wrong terminology from me there - I mean a dropped pot or baffled area within the tank to stop fuel starvation??

I would think that you need something along those lines, as the pump needs to have a constant feed.

got the t shirt


and have another GTM tank to modify for a friend for their injection zetec mini.

Easy way to do it, drain tank of fuel, fill tank with water, empty, fill again , cut open tank leaving as much water possible in the tank and being careful not to get too hot, ideally use a jigsaw hole saw as they put in less heat than a cutting disc.

I have a pot in the bottom of my tank which the injection pump sits within, with the return entering in the side to create a swirl within the pot to remove any aireration. This pot extends above the bottom of the tank approx 1 inch and has a couple of holes drilled into it to allow the pot to fill when the tank is low on fuel, from memory the pot itself holds 0.5 litres on its own. and works very well, never experianced any surge, have ran down to empty in a test to empty the tank out of fuel and the pump had picked up everything but the last 5mm in the bottom of the pot.

Once ran out of fuel as i entered a forcourt and i did not have any noticable surge untill it conked out as i turned in and i had just been breaking a few 100 yarsd before for the turning

Ill have to see if i have a picture of the internals, i recently had my tank open to change the opening and install a larger pump. when i did this i had a little welding to do to make the opening smaller, so i did as above filled with water a few times, then dried it out, then wiped it out with de greaser, washed out with water again, then once happy there was no fuel left i carefully welded up the tank a small section at a time and with dad as fire marshall and fire extinguisher at hand.

Personally i think a tank can be welded up if you are meticulous with cleaning it out, and have the option of opening the top like i do so as there is no chance for fumes to trap, and if you really go over board with cleaning/washing it out.

WEST

Ok, plan is: wash out with detergenty water a couple of times, then leave to soak overnight with a 200:1 phosphoric acid mix to leech out the petrol from any pores in the steel. Then flush again and leave full.

I'm going to see whether i'll get away with cutting only, without any welding - I might be able to tap the plate thats already on the top of the tank.

When I last had to weld a fuel tank I ran the exhaust of another car into the tank, this purged the fumes and dried the tank. Best to then wash it out as well.

I modified my tank too as I didn't like the filler position and on opening I found no baffels either, I cut the entire top off so (jigsaw) I didn't have to worry about fuel vapour but I have in the past used both the water and exhaust methods, watch out for the water one as if the tank is left for any period the water residue will rust the inside surface of the tank.

I've just had the idea of the day - i've got a pile of damp sand around the back of the house

After a good internal washing, this should surely be easier to work with than a water filled tank.

And I know what you are going to say, but the holes I will be cutting will allow me to get right inside the tank with a jetwasher lance to get all of the sand back out again when not needed.

Be carefull with sand as its amazing how hard it is to get out of sealed/limited access boxes, we have similar probs on nour heavy machery.

I see your point, but I think i'm going to silicone paint the inside when i've got it open so any errant granules should get trapped in this.

Can you not use your standard tank   , and fabricate a small tank just big enough (stand alone from the gtm one) to house the pickup unit in the Mr2 sitting a few yards away . Pump from the GTM tank into the small one, then on from this one with the standard made to measure pump for that engine . No welding at all      Or am I being dumb MIssing something

I do'nt think you are missing anything Stuart, the only thing is i think Phil is trying to get away with 1 pump.

Yup, the amount of stuff that I still need to find homes for is ridiculous. The shelf under the frunk will be full, under the dash is already full, and i've still not fitted the heater matrix. The centre tunnel will be full, and the engine bay will be over-full - so anywhere I can simplify things will be a help.