On removal of the fuel tank it didn’t look too bad and there was no sound of rust rushing about inside, if I were to use it again it would have to either be run with an external or an internal fuel pump and as I like a challenge I decided for the latter, a pump from the same car the engine came from, I obtained a pump from a civic with the same engine and checked it out against the tank, depth was a perfect fit and the rest of it seemed to be too, the only problems I had now were where are the baffles in the tank and how do I remanufacture the opening for the pump to fit…
After browsing the net I fortunately came across these images, result…
Brilliant the pump will fit between the baffles and I know where to cut the hole…
Hmmm next was how to fit it, I could either cut a civic tank up and use the interface from there and weld it into the tank or I could do it the hard way and do it properly so I opted again for the latter…
First I had to design and make a tool to create the swaged edge for the gasket to seal against, so into work, knocked up a tool and then done this…
Get old tank…
Mark out and cut holes…
Trial fit pump..
Fit tool and tighten, loosen, turn, tighten, loosen turn etc …
Remove the tool and hey presto a nice swage…now for the fixings…
Clean interface in and out and clean fixings.
Silver solder fixings In one by one allowing to cool at each fixing.. (NOTE: Ensure the tank has been completely cleaned off any fuel vapours if you want to try this at home, I will take no responsibility if you blow yourself up)
All done and pump now fits.. now to make it clean and sealed inside and nice on the outside
