Hi all,

Got 3 autocrosses on my car and absolutely loving the car and having a blast, but I'm starting to get pretty frustrated with my fuel tank. I have the "old" style tank that was before they made the firewall cut for more driver room. The connections for the fuel pump and level sender are the style that use a 1/4 turn ring, not using the Subaru tank top mount. I had to hack together the Subaru pump to the supplied top bracket. I think this is the tank that shipped with the earliest kits, with the older front-end.

I cannot seem to get the 1/4 turn flanges to consistently seal. I've had them both on and off many times. The O-ring (not really an O-ring, looks more like a rectangle section) doesn't really index well into the hole, and the diameters of the mating flange vs the O-ring are such that it is very easy for the o-ring to slip out on one side. I have had this happen over time too, so even if I pressure/smoke test and verify it's all sealed up, there's no guarantee it will be tomorrow.

Second but more minor issue, the fuel level sender is either getting its float stuck or just has intermittent shorts/opens. My fuel gauge is pretty much a random number generator between totally full and totally empty. At one point it sorta worked, but lately I've had it on and off like 5 times and I can't seem to get it to stay consistent. It'll be reading ok, then I'll go around a corner and then it'll jump to some random position (usually 100% or 0%, but sometimes somewhere in-between) and just stick there until I take it out and back in again. I've tried a ton of different orientations.


Has anyone gotten to a point where they're happy with this tank? I'm wanting to get it reliable before my next autocross mid-May so I don't have the lingering fear of fuel spilling onto the hot headers constantly in the back of my head. I was going to start with pulling the fuel pump and level sender both out, measuring the O-ring groove, and ordering a better set of O-rings from McMaster. For the sender, I guess I'm just going to keep iterating with orientation of the float and maybe try bending the wire and try to find a spot where it doesn't bind up. But this kinda seems like something that could be a never-ending battle, I'm wondering if I should just consider either the Boyd tank or a fuel cell and know I have a solid solution.