So you’re sold on doing an EFI conversion, perhaps one of the easy self-learning systems profiled elsewhere in this issue. Pretty much any company marketing conversions will have you taken care of with everything needed from the engine to the fuel system upgrades, but what about the fuel tank?

While you can technically run an EFI system with any factory fuel tank, the problem is that older tanks, typically pre-1980s, don’t feature any sort of baffling or sump; it’s just a big open chamber for the fuel to slosh around in. Such is the case with the fuel tank in Project EcoNova, our ’76 Nova project car and its LS3 E-Rod conversion. With the low pressure and flow associated with mechanical fuel pumps, that’s not too much of a problem for daily driving situations. EFI pumps, however, flow much more fuel at around 10 times the pressure—something our Nova’s E-Rod conversion would demand. If the tank is below half to a third full, just exiting a freeway ramp could be enough to create a fuel starvation issue that could damage the pump, or even the engine. If you’re planning to do any sort of performance driving like autocross or open track (that’s us!), forget about it, you absolutely need a baffle of some sort to keep fuel around the pump.

…the problem is that older tanks, typically pre-1980s, don’t feature any sort of baffling or sump…

There are some great ready-to-go EFI-prepped tanks on the market, but they tend to be pricey, and model-specific applications will only be the usual suspects, Camaros and Mustangs and so on. So what do you do if you’ve got a project with no direct-fit option—such as a ’76 Nova—and you’d rather avoid a universal fuel cell? No worries, we’ve got the solution. There’s a quick, easy, and cheap way to prep just about any tank for EFI. Even with a killer pump like the new Aeromotive 340, we still came in around $350 total. Not bad at all considering we didn’t reuse anything from the car, and we finished it off in a day. Better yet, all the work is on the top and inside the tank so it retains its stock looks, and with an in-tank pump there’s no telltale whine either.

Note of Caution:

We recommend using a new reproduction tank that has never been filled with fuel of any kind for this mod. If you choose to reuse an old tank, do not attempt to cut or weld on it until it has been professionally cleansed and rendered inert. Some fuel tank or radiator resto shops can handle this, but ask first and tell them what you’re planning to do. Don’t try to clean it yourself, and don’t trust advice on the Internet—old fuel tanks can, and do, explode!

No worries, we’ve got the solution. There’s a quick, easy, and cheap way to prep just about any tank for EFI.
SOURCE
Classic Industries
18460 Gothard Street
Dept. CP
Huntington Beach
CA  92648
800-854-1280
www.classicindustries.com
Aeromotive
7805 Barton Street
Lenexa
KS  66214
913-647-7300
http://www.aeromotiveinc.com
Miller Electric
1635 W. Spencer Street
Appleton
WI  54912
920-734-9821
www.millerwelds.com
BS Industries
818-768-7600
www.BodieStroud.com
HarborFreight
3491 Mission Oaks Blvd
Camarillo
CA  93011
800-444-3353
www.harborfreight.com