I finally got to modify my fuel tank.
It's pretty straightforward and easy to do.
First, here's the tank. I have 2 tanks and I picked the one that looked like it's in the best shape from the outside.
Here's what it looks like inside...
From the filler neck
From the fuel sender hole
And the fuel sender. The second one is even worse.
Since I'll upgrade my cluster with Speedhut gauges, I decided to use a 9 inches Fuel Level Capacitance Universal Sender from them.
That being said, I settled on installing the pump in the center of the tank between the 2 baffles, as far back as possible.
Side note, I'm pretty sure there's enough room to install the Tanks Inc kit to the far left of the tank with the tray facing the right side to retain the original fuel level sender unit.
The top plate has to sit on a 6" flat surface.
I used a hole saw to drill the 4.5" hole.
I placed the tray/pump baffle inside the tank to check for fitment against the original tank's baffle.
The instructions says to put the tray sideways, so facing left or right.
As you can see, the tray is resting on the baffle and it is not centered on the hole.
I tried rotating it towards the back, but it was impossible to have it centered while sitting flat at the bottom of the tank.
The tank's baffle needed a notch for the tray to sit in the right spot. I managed to stuff my Dremel inside the tank with a flashlight to do the job.
Now, time to cut the pump bracket for the tank depth.
Measure twice, cut once.
Perfect fit, the plate is sitting flat on the top of the tank.
Now... remember I said to drill a 4.5" hole? Well... I used a 4" hole saw by mistake.
So I needed to cut 2 small notches to be able to drop the assembly inside the tank.
Assembly ready for test fit...
Everything looked good so I marked the fasteners locations with the assembly in place to make sure the pattern clocked properly.
Take your time while drilling, I had a couple of holes slightly off that needed rework to fit.
Done and back in the car so I can finish my fuel hoses/lines routing.
I wanted to clean and refinish the inside of my tank with the POR-15 Fuel Tank Repair Kit and finish the installation of the pump, but believe it or not it's too cold in the garage & in the basement to use the products... I'll have to wait till spring.