Fuel Tank
I had hoped that the stock tank would work OK with the EFI, but it soon became clear that it was a bad match. Anytime the tank was less than 1/2 full, slosh would uncover the fuel pickup when turning hard. With a carburetor this is not a problem, as there is plenty of fuel in the carbretor bowl which keeps the engine running until fuel once more covers the pickup. With EFI, however, an air bubble is pumped into the fuel rail. Result: major bucking as air is pumped into the engine instead of fuel.
The fix was a custom aluminum fuel tank with internal baffling and a sump. I was sent on a short term contract to Sweden in the fall of 2002. I have a friend there who has a fab shop. He built me a custom tank, all out of aluminum.
This is the bottom half of the tank during construction. The side pieces are not installed yet and you are getting a good view of one of the baffles. The triangular cutouts on the bottom is so the fuel can flow around in a controlled manner.
And here is the finished tank. Highlights:
Uses factory fuel level sender in factory location.
Uses factory filler neck.
0.8 gallon sump with drain plug.
3/8" NPT return line fitting on drivers side.
3/8" NPT fitting for vapor recovery on drivers side.
3/8" NPT fitting for fuel pickup in sump.
2 internal anti-slosh baffles.
Allows use of spare tire carrier and does not decrease space for mufflers.
Holds 21 gallons, including sump.
Weight: 17 lbs.