I had a look inside a Ford Granada fuel tank my dad had lying around today. This had an internal 'swirlpot' arrangement which sat in a very slight recess/sump (about 15-20mm deeper than the bottom of the tank). The internal pump and fuel level sender unit was very similar to the Mondeo one I have.
I am now planning on folding up a similar 'maze / spiral' that will allow for my 'L' fuel filter/pick-up to sit inside. I will cut a hole in the base of my tank and slide this in such that around 20mm sticks out below and a further ~50mm sticks up above. This will then be sealed on the outside with a small side blanking plate and a sump floor plate.
I will then make an insert with a sunken lip to allow my Mondeo pump/level sender unit to sit down lower than the top of the tank, such that the 'L' fuel pick-up sits on the floor of the sump.
I'm confident this will work; it seems to work for Ford! Your thoughts though, please?
Josh