I installed this home made through-tank fitting in my tank. I copied one from McMaster, using eight 3/8" studs instead of their four 1/2" studs. It will feed my auxiliary pump. The pump will run by a pressure switch, coming on at one psi boost. The in-tank and the auxiliary will feed a tee that has check valves on the inlets, and it will feed the fuel rail. The fitting is 3/4" pipe, from there to the pump will be -12 AN lines. I think that MagnaFuel told me to feed the pump with a minimum -10 line.
Installing the fitting was interesting. I hole sawed and drilled the tank using the outer plate as a guide. I then fed my electrician's fish tape through the hole to the fuel bucket hole. My buddy grabbed the tape, and slid the fitting down towards the exit hole. We played jump rope with the tape inside the tank until the fitting found the light of day, and I grabbed it with a 3/4" pipe nipple.
I know it is just feeding the pump from a hole in the bottom of the tank and not a sump with trap doors, but I think it will be OK, because:
1. It is in the rear of the tank, and the fuel will have sloshed back there by the time 1 psi of boost is reached,
2. When I let off the gas pedal, or hit the brakes and the fuel uncovers the outlet, the pump will be off anyway because there will be no boost.
The middle picture is the slug from hole sawing the tank.

 

Not quite a year. It worked, fed the pump plenty of fuel, but it was a bad idea. Yesterday it started leaking about a 1/8" stream of gas. I think the gasket might have dissolved. No matter, it's inside the tank, no repairing it. I was standing by the driver's door, doing some idle tuning when I started smelling gas. How lucky that I was right there when it started. The boneyard had a used tank for $75 (First one they sold, "what happened to yours?"). I think I'll do a surge tank now.
As heavy duty as my fitting is, and with so much gasket area, I wonder about the guys I read about in LS1tech that did the same thing with a bulkhead fitting. Those are just a little bigger on the OD than the pipe size you are using, and the gasket area is only about 1/8" wide. Seems risky to me.
Kids, don't try this at home.

As

 

custm2500, thanks again for trying to help me out, I just couldn't wait to get your tank shipped.

 

No problem.

 

sucks.........I remeber when you did this. Suprised it lasted as long as it did. Thanks for posting so others don't make the same mistake.

DBrods in San Antonio makes a very nice custom aluminum tank that could get what you need done. I'd give him a call and scratch the surge tank idea. The surge tank works, however in my opinion its pointless due to cost, and complexity. If you going to build a tank and plumb it, why not just make it your fuel tank? Simplicity is the key in my mind.

 

That's all I need to hear Sounds like a project for MikeGyver!

 

Fuel cells use a bulkhead and everyone with a fuel cell has them. I don't know why you were so scared of the bulkhead. I have two of them in the sump of my cell and have no concerns about them lasting.

 

I see what your saying, as my cell has a bulkhead fitting in it too. But for some reason, almost everytime I've seen someone try to modify a stock plastic tank like that.....they've leaked. I don't know why.

 

Do you mean like this, and not welded-in? The fitting in the link is the kind I'm talking about guys putting in plastic tanks. There sure is not much gasket surface there. I'm sure it would be fine in a metal tank, but not plastic, in my opinion.

 

Well like I said I have two of them in my fuel cell and expect them to last forever.Tank is plastic and like I said EVERY fuel cell I have ever seen has them. That is what they are made for.