Guys & gals,
I've been wanting to get rid of my stinky surge tank and fuel system for quite some time now. After looking at a few methods I decided on how I was going to approach it.
Parts you will need:
1. BA/BF Falcon Ute Fuel Pump Cradle (XR6T/XR8 Version has a larger pump good for 250+rwkw).
2. 2x Falcon fuel pump retaining rings. These can be removed from any Falcon. Sedan is easy as it is under the rear seat. You will get 1 ring per car.
3. Wiring connector from Falcon.
4. Stock clean fuel tank.
I have chosen to use a falcon cradle as the pump is easily upgraded (Walbro, Deatchwerks etc), the mounting system to attach the pump is simple, it has an internal swirl pot and the total overall height is easy to modify.
Anyway, pics.
1. Remove the original sender. You can easily just cut off the boom arm and float and put it back in to seal that hole. I had mine welded up.
2. Find the approximate centre of the tank (Left to right) and mark it. You want to drill your holesaw hole a little more to the rear of the tank to make allowances for the new fuel level float.
3. Drill your hole.
4. Weld in a falcon retaining ring.
5. Disassemble the pump cradle and cut 12cm out of the rods that hold the top and bottom together. I had to cut off the ends that had the retaining barbs, which means the pump pops out when not held together.
6. Cut the Falcon float arm to remove the float. Bend the arm 90 degrees to make it shorter. Pop the float back on and crimp the end. Pretty simple really. You want to ensure the float has full range of movement inside the tank.
7. When the pump is installed, the cradle needs to bottom out on the floor of the tank and then you simple push against the internal spring between the top and bottom to seat the pump into place. Simples.
8. We drilled small 'starter' holes in the metal of the tank to allow us to use a coarse screw to anchor the pump. Also a sealing gasket needs to be used to seal between the pump and the ring welded to the tank.
** note: the sender's resistances are different, the stock gauge probably won't work. I have a programmable fuel level gauge in my car. **
Welding all done. The top of my tank has been chopped to accomodate a battery hanging from the parcel tray.