Fuel Tank questions answered.

[dickspanner]

Hello, As some of you know I have installed a 2.9 cossy motor in my crewcab and over the last several week I have been trying to sort out the fuel tank issues in relation to fuel starvation round corners etc.

I was 100% sure I was going to go down the twin fuel pump and swirl pot route and someone mentioned the 2.1 fuel injection tank as it had baffles and a swirl pot etc.

I decided to go down that route and sourced myself a tank.

Important bit now!!!!

I decided to have a look in my old DG tank and cut a wacking big hole in it to have a look inside as nobody could confirm the questions I was asking.

The DG tank (1.9 litre petrol normally asperated) HAS baffles in it, The tank is fed from the bottom (round recess visable from underneath) and has 1inch high bafflkes in it to prevent fuel starvation. So it may not be necessary to go down the route I have gone.

I cut a hole in my tank to mount the pump support ring from the cosworth and am now going to have the ring tig welded into place so I can fit a cosworth race swirl pot in the tank and the cosworth fuel pump.

[img:800:600]http://i110.photobucket.com/albums/n103 ... affles.jpg[/img]

Baffles in tank

[img:800:600]http://i110.photobucket.com/albums/n103 ... intank.jpg[/img]

Baffles in tank

[img:800:600]http://i110.photobucket.com/albums/n103 ... thpump.jpg[/img]

Cosworth swirlpot and pump assembly

[img:800:600]http://i110.photobucket.com/albums/n103 ... intank.jpg[/img]

Swirl pot in tank. Note the positioning of the swirl pot in this location makes the fuel sender redundant, so I am going to have to modify the cosworth fuel sender to work on the VW system.

[img:800:600]http://i110.photobucket.com/albums/n103 ... mpring.jpg[/img]

The fuel pump support ring, I am now sending this assembly off to the tig welder who makes fuel tanks to it cn be welded and tested.

But going down the route I have chosen, the fuel pressure/delivery system, is as the original installation and now if I have any problems I can drop my tank and change my internal pump etc.

This has been a real ball ache for me in deciding which way to go, but I decided this way, although is more work, removes any doubts I will have about the fuel delivery system to my engine. Oh yeah, the welded will weld up the original drain and return fuel points on the tank as well, and spot weld the swirl pot in place to the base of my tank.

I hope this has answered some peoples doubts about their fuel tanks etc, and the suitability of a tank etc, but I can not be held responcible for I told you so senario, this is only my findings, when I cut open my tank and my solution.

Cheers

Dickspanner

[markscoot]

Nice work fella. Have you managed to peek into the 2.1 tank to see if it had a swirl pot fitted.
That was the 1.9 tank you cut up wasnt it?
My tank is a diesel an it is suffering from scooby swirl.Gotta get another one,gonna go for 2.1.

[vw nerd]

I think that my experience after fitting a non genuine injection fuel tank could be of help here.

When building my bus the original tank was rotten along the top edge.

So this was a good time to treat the project for a brand new rust free tank.

I looked at the price of new and fell over...So I bought a new non genuine one from a well know supplier of bus parts.

If the fuel level is bellow the last 1/4, I get fuel starvation on corners.

So do the non genuine injection tanks have the same swirl pot as std vw tank. Any thoughts???????

You have been warned. New is not always better if non genuine!