TRX' Fuel Surge Tank

This is the fuel surge tank for Tyrannosaurus RX. A 6 PSI inline pump near the tank will keep this tank full of fuel; a smaller return line runs overflow back to the main fuel tank. A 155 lph high pressure pump gets mounted in this tank, which will have short -6AN braided steel lines connecting it to the fuel rail and fuel pressure regulator. I've seen too many EFI cars burned down to the ground to trust rubber hoses or push-on fittings at 45 PSI.



Here's the 3.5" aluminum tank, the 2.5" baffle (note spiral holes to break up any bubbles in the returned fuel), press-fit counterbored bottom cap and top ring, and round top cover. Everything except the cover is TIGged together. Then the radial fuel inlets and outlets get welded on.



Drilling a piece of 1" 6061-T6 round bar. For one of the radial inlets. Yes, its' hung out there a long ways, but it's not a deep hole and it was deeply center punched. Even if it wanders a little to the side it won't matter much.



Setting up the boring head. The diameter is set to the same as the OD of the piece of tubing I'm using for the surge tank.



Here I am flycutting the bar.



Now I'm whacking it off with the band saw, with a little left on the end for facing off in the lathe. The fitting looks sort of like one of those patent nose pair removal tools, doesn't it?



Now I'm boring the hole a little larger before chamfering, running the taper reamer in, and tapping 3/8 NPT.

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01/00 - the main tank is welded up, the radial fittings are done, there's a big pile of AN fittings, a pump, etc. I need to make the nylon bushings to pass the wiring through to the pump, make a bracket to hold the pump in place, and weld on the radial fittings. Just a simple matter of round tuits now. I've already made the mounting bracketry, with nice rubber isolators.
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