Fuel Tank for Injection Engines

[Josh]

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

[voucht]

When I read your previous post, that is exactly what I thought about. Same system in the fuel tanks of EFI Sierra, and I guess it really avoids fuel surge. If you build a similar "maze" in your fuel tank, I think you are safe. Just my modest opinion though...

Another thing, if the "L" shaped filter of the Mondeo takes too much room, you can have smaller ones ("I" shaped ), like the one from the EFI pump of the Sierra (you can see it on the last pictures at the very end of this post of my blog: http://vouchtroadster.blogspot.se/20...reservoir.html)

I bought a brand new one from FSE Glencoe. I've been working with this company for 15 years, and they are in the UK, you can order one from them, you have the choice. Just check the diameter of the fitting, but I'm sure you'll find something to replace yours if you need to.
http://www.glencoeltd.co.uk/walbro-f...in-tank-parts/

Good luck

[alga]

Very smart!

One more consideration. The swirlpot below the bottom of the tank allows one to run the tank to nearly empty, not to mention the 1 l of extra capacity it adds. This design will require a couple of litres left in the tank for the pump not to suck air.

On my 2l Zetec with factory ECU the fuel usage is ~8.5 l/100 km, meaning the range is below 300 km.

I took a pic of my swirlpot when the tank was out:
http://imgur.com/4eZ7pIh

Here you can see it stick out at the back, as you see it's not in harm's way:

[baz-r]

Originally Posted by alga

Very smart!

One more consideration. The swirlpot below the bottom of the tank allows one to run the tank to nearly empty, not to mention the 1 l of extra capacity it adds. This design will require a couple of litres left in the tank for the pump not to suck air.

On my 2l Zetec with factory ECU the fuel usage is ~8.5 l/100 km, meaning the range is below 300 km.

I took a pic of my swirlpot when the tank was out:
http://imgur.com/4eZ7pIh

Here you can see it stick out at the back, as you see it's not in harm's way:

very like mine and mine works a treat
external pumps make life alot easier
put a baffle at the center like wit a hole under it so left/right slosh keeps it full in the corners

[Josh]

I've found a company that can weld my ali tank for me and I'm keen to get this done next week. However I have not decided which fuel filler cap I'm going to use yet - do I need one to know what diameter to make the neck on my tank that the filler hose will connect to? Or is there a standard diameter?

[Josh]

Also, what is a fuel nozzle insert, and why do I need one fitted to my unleaded vehicle for it to pass the IVA?

I'm thinking now that I might neglect to have an external fuel filler cap mounted on my rear panel and use a motorbike style fuel filler cap mounted directly on top of the tank.

More boot space this way as there is no filler hose in the way, but maybe a bit annoying to get to when the boot is full. Thoughts?

[snapper]

Some fuel filler caps (aero style) have dual size built in so pick you cap then get tank neck made to fit
If I remember sizes are 55mm and 50mm last being most common
As you can't buy leaded fuel any more I think the restrictor flap thingy is not needed
Car Builder solutions have filler caps and dimensions