Fuel Tank for Injection Engines

[Josh]

Update on my fuel tank progress (and questions!)

I have folded the main section of my tank from 2mm half-hard ali (left over sheet from my floor). It is exactly to the book specification; however it's a very (very!!!) tight squeeze to get it into position on the car. And I think the tank is deforming slightly as I push it in - it won't be able to do this once the tab has been welded in place and the sides/baffle welded in. Is there a trick to getting the tank in other than force in from the top?



I've brought myself a Mondeo in-tank fuel pump and level sensor which I plan to fit into the top face of my tank. It's just the right height to have the L-shaped fuel filter/pick-up sit just off the floor of the tank.

I'm thinking of constructing an internal swirlpot to prevent fuel starvation. This would probably be four 'walls' that sit around the 'L' with many small holes to prevent fuel rushing out. Will this work? I'm thinking the walls will have to be high enough to stop fuel rushing out over the top.

Thanks
Josh