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| Video: Testing baffled and sumped fuel tanks https://www.slantsix.org/forum/viewtopic.php?t=68504 |
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| Author: | MadScientistMatt [ Sat Jan 17, 2026 7:32 am ] |
| Post subject: | Video: Testing baffled and sumped fuel tanks |
Baffles or sumps can help avoid losing fuel pressure while cornering with EFI. This is a quick video I put together where I have tested a couple model fuel tanks to demonstrate the basics of how baffles and sumps work, and how you can test out more advanced ideas on your own if you want to give it a try. Baffled fuel tanks on YouTube |
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| Author: | Dart270 [ Sun Jan 18, 2026 8:17 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
Nice and simple. Thanks, Matt. Lou |
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| Author: | MadScientistMatt [ Wed Jan 21, 2026 5:04 pm ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
You're welcome. Since I've mostly just been driving the Dart lately and looking to see if anything needs fixing, I needed a different subject for a tech video than just me working on the car. Youtube has an "AI brainstorm ideas" feature, and most of the ideas were terrible, but it did mention an idea about baffled fuel tanks and I realized I could demonstrate that with a shoestring budget. I'm glad you liked the video. |
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| Author: | lgu32 [ Mon Jan 26, 2026 10:36 pm ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
Have you tried to made baffles to a complete tank? I think it would be quite a complex work to get running. At least a lot of welding for it.  In the picture at the side of the radiator I have a surge tank. I will solve the same problem but totally different way. All the bubbles coming from rear tank are separated at the surge tank for fast return to rear tank. I did this because I didnt want install anything new to original tank. |
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| Author: | MadScientistMatt [ Sat Jan 31, 2026 8:19 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
Yes - my Dart has a bread loaf pan from Wal-Mart welded underneath the fuel tank. I finally had to use some epoxy to get the last of the pinhole leaks as my welding skills aren't the greatest. The oil pan baffles were a lot easier since I just had to tack weld that (which started out as a cookie sheet, making for two pieces of cookware that found their way into my car). |
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| Author: | lgu32 [ Sat Jan 31, 2026 10:09 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
Ok. I did once a fix for a 50cc minimoto fuel tank with mig welder. Found that complex with my welding skills. There is many ways to get the same end result. When I build my 1st fuel injection system to my -66 I was doing it in a garage where such a fuel tank removal was difficult. So I chose the straight way. I kept the original mechanical fuel pump for circulation between main and surge tanks. Do you have or do you build return line to tank? |
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| Author: | MadScientistMatt [ Sun Feb 01, 2026 5:55 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
The return is generally pretty easy. With the sumped tank, I am using the original pick-up tube for a return. Previously I had simply drilled a hole in the tank and run a bulkhead fitting. However, that tank rusted out and I needed to remove it anyway, so I figured I might as well weld something together while I had a brand new tank with zero gas fumes inside. I previously had a surge tank combined with a fuel filter. Didn't like the complexity of two pumps though. |
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| Author: | lgu32 [ Tue Feb 03, 2026 10:53 pm ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
We got two different results with the same parameters! |
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| Author: | mcnoople [ Wed Feb 04, 2026 5:49 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
I have thought about adding baffles to the bottom of my valiants tank. I could never bring myself to cut up the rusty original for testing. The method I eventually figured would work best was to make a light weight tray with thin gauge metal very similar to what is in the video. It would need ramps leading up into it with 90 degree walls to keep the fuel in. My sorta crazy plan was to slip the tray/sump/baffle in through the sender and then crimp/rivet the seams through the sender hole. I figured the best method to hold the baffle in place under the pickup would be to use lead. Place the baffle in the bottom of the tank and then heat the bottom of the tank until the lead in the tray melts and adheres to the bottom of the tank. I never tried the method because I could never decide if I wanted to build an access hatch in the top of the tank. Since the repro tanks with baffles aren't stupid expensive I might go that route if/when I go to EFI. |
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| Author: | MadScientistMatt [ Wed Feb 04, 2026 5:58 pm ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
A ship-in-the-bottle build for a baffle? That would be an interesting trick. Might be easier to slice the tank along the seam and weld it back together there. One idea that's gained popularity recently is to cut a hole in the top of the tank and then use a gasketed piece of sheet metal bolted over it. Usually that's to drop in some sort of fuel module, but it could also work for an access hole. I thought about trying an upside-down version of the sump drilled full of holes like a collander, with a large hole in the top for the pick-up to go through. |
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| Author: | lgu32 [ Sun Feb 08, 2026 2:29 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
If a man is doing just a single fueler from A-body and uses plenty of time testing tank baffles, tank sumps etc where is the gain? When ever the prototype has a problem it is a new tank removal. Be careful when welding used tanks. |
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| Author: | MadScientistMatt [ Sun Feb 08, 2026 11:31 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
The sumped option is very simple if you have ground clearance for it. If you're worried about clearance issues, that was why I suggested getting some sealant and food storage containers and testing your idea out in plastic before you make it out of steel. |
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| Author: | lgu32 [ Mon Feb 09, 2026 11:31 am ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
If the target is just drag race probably the location of pump in the rearmost side of the tank is enough. But if there is idea for fast curvy roads then the deep sump is needed. I dont think a baffle will keep the fuel delivery in order in the circle track. I used ChatGBT today to made some calculations how a 1/4 full tank fuel goes when cornering. A realistic 0.7G side acceleration will dry about 1/3 of the tank floor from all the fuel. In my H-D Sporster I fill the tank to top before going to my favourite curved roads. It has external pump sucking from the petcock and it really shot the exhaust when it get air thru the injectors. |
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| Author: | MadScientistMatt [ Mon Feb 09, 2026 5:21 pm ] |
| Post subject: | Re: Video: Testing baffled and sumped fuel tanks |
You don't need a very deep sump if the holes between it and the tank are sized reasonably. The sump in the video took a while to empty even when the "tank" was tipped on its side. |
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