How I do internal fill....

Cannibal

Tasty Human
Location
Summit Lake, WA
...in 3 easy pictures....

Parts:
2 - Swagelock bulkhead fittings, 1/4" McMaster PN 5272K231 (cheaper on ebay)
2' - 1/4" stainless steel tubing sourced local, but McMaster has it too. Copper or Aluminum would work too.

Process:
Drill a couple holes where you want them. I like where I put them because it's the rear of the tank, where the fuel will be during acceleration.

Cut off your 'flange' and hog it out a little to fit stock filler (or any after-market one you want).

Cut your lines to the length you want. I made mine 1/4" from bottom for reserve, and about 2" from bottom for main. This means less reserve, but I like that. I've flipped to reserve and ran out because I have so much fuel that I forget how much time went by since flipping. Now, I will flip to reserve and head in shortly.

Insert your tube into the short side of the bulkhead fitting and lock it down.

Goop up your fitting where it will seal to the tank. I used Honda bond. May not be the best to use, but it's what I had. If I need to reseal it, no big deal to remove them and put something else.

Insert tube/fitting assembly into drilled hole from inside of tank. Goop up where lock nut will snug against tank and install lock nut. I have stubby wrenches, so getting one in the tank was no big deal. Tighten lock nut.

Clean your tank, you'll have some crap in there.

Install your filler using ss screws and stock gasket. Check for leak using water, may need to goop this too.

Just install a little of the remaining 1/4" ss tubing on the top or make an elbow to hook your fuel line to. I may try to flare the tube a little to form an end barb, but I don't think it's really needed. There's no real pressure on these hoses.

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Cannibal

Tasty Human
Location
Summit Lake, WA
so you just glued it on?

let us know how long that last.

Sorry, glue what on? The fittings are a bulkhead fitting and insert from inside the tank with some sealant, the filler will be screwed down with stainless hardware and sealed with stock gasket and maybe some sealant, tank will be strapped down, I'm in the middle of a build and did this while waiting for glass to harden.

holey bpipe screw

Those are the BK twisters available here.
 
dont use 'goop' on the filler. even 1211 will deteriorate and clog your tubes and/or filter.

just use a new oem gasket for under it. when you pre-drill the holes for the 6 screws, use a much smaller bit than you would as if you were going through metal.
 

Cannibal

Tasty Human
Location
Summit Lake, WA
dont use 'goop' on the filler. even 1211 will deteriorate and clog your tubes and/or filter.

just use a new oem gasket for under it. when you pre-drill the holes for the 6 screws, use a much smaller bit than you would as if you were going through metal.

I'm going to try to run the filler dry. If that doesn't work, I might cut a cork gasket and give that a try. I'll use some sealant as a last resort.

Good point about the bit. I've drilled stuff in plastic like I was doing metal and had it not hold. I always seem to forget this.

Wouldn't that suck air real bad when you are nose down doing stabs and such?

You'd have to be pretty low on fuel in the first place, and I can't imagine it would be any worse than stock, which never really seemed to be a problem for me.
 

GIL

Power In The Hands Of Few
Location
Cullman AL
I'm going to try to run the filler dry. If that doesn't work, I might cut a cork gasket and give that a try. I'll use some sealant as a last resort.

Good point about the bit. I've drilled stuff in plastic like I was doing metal and had it not hold. I always seem to forget this.



You'd have to be pretty low on fuel in the first place, and I can't imagine it would be any worse than stock, which never really seemed to be a problem for me.

Mine is nearly identical to yours as well. I used the oem gasket between tank and filler only and predrilled tiny azz holes for the oem stainless screws. 2 years now and NO issues yet.
 
a new gasket will be fine w/o sealant as long as you drill TINY holes.

also, its a good idea to drill some holes near the top of the filler (under the flange, though). this allows you to fill the tank up all the way instead of just to the bottom of the neck.
 
Here's how I closed my old filler neck. Slick as :):):):). Check your local truck parts store for one of these bad boys.
 

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