|May 22, 2012 - To avoid the problem of the baffle segregating the tank into have and have not sections, I drilled a few holes.|
They won't allow rapid flow of fuel from one side to the other, but it will be enough to let me use the full tank capacity. Between this and removing the giant sealed off canister, I've probably doubled my tank capacity.
Once this was done, I cleaned out the tank and started welding. First, the big round baffle was tacked into place. Then the fuel lines were welded in. The original fuel pickup was welded shut. And finally, the fun job of welding the top back on again. I used a MIG welder for this which does usually leave some pinholes, but I did my best to get a good seal. I also spread some gasoline-resistant liquid metal over the seam to catch any little leaks. The seam is right at the top of the tank so it's unlikely to ever be wet on the inside, but I still don't want any leaks!
tags: packaging, suspension, fuel tank