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Budget In tank fuel pump

brianstrange

Bronco Guru
Joined
Nov 22, 2011
Messages
1,626
Okay, the following write up is for a 77 style plastic tank. The set up is un teasted, but I've done similar systems like this in the past, and they worked fine. Please keep in mind that my tank doesn't have a tray in it so if you do this mod, I suggest you don't run too low.
 
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brianstrange

Bronco Guru
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Nov 22, 2011
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1,626
Tools required:
Drill
2 1/8" hole saw
1/16" drill bit
3/16" drill bit
Small vice grips
regular screwdriver
5/16 socket & ratchet
soldering iron, solder & heat shrink (or crimp connectors & crimper)

Parts Needed:
5.0 Mustang fuel pump & strainer
Tanks INC. in-tank pump hanger & hardware (SSP-1 In-Tank Fuel Pump Hanger Kit $50)
Tanks Inc. threaded "C" Mounting Ring (3TR Threaded Mounting Ring 6 Hole 3-1/4" Diameter $8.00)

The pump pictured is for reference only.
 

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brianstrange

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Nov 22, 2011
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The first step is to remove the factory sending unit, and flip the fuel level float from left to right while looking at the top of the sender as it sits in the hole. This is also a good time to block the stock fuel pickup, as it will no longer be used.
 

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brianstrange

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The in tank pump hanger will be mounted in the recessed cavity towards the front of the tank. Be sure to clock the hanger to your application, as the outlets are in a fixed position. Offsetting slightly to the drivers side, will help offer the lowest part of the tank to the pump strainer. Use a 2 1/8" hole saw, ad drill the main hole for the assembly (ring is 2 1/4", but the tank will melt just a bit while cutting.) Once positioned, use the threaded "C" plate as a template and drill 1/16" pilot holes for the pump hanger bolt circle. Remove the "C" plate, and enlarge the holes to 3/16".
 

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brianstrange

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Nov 22, 2011
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After enlarging the holes, use some silicone or gas resistant adhesive, and slide the "C" plate to the inside of the tank. It can be tricky, a set of vice grips will be your friend here. Once on the inside, use the screws provided, and tighten the plate to the tank. This is also a good time to measure the tank depth to the deck of the mounting surface. Be sure to measure from 2-3 points, as you may find a slope in the tank.
 

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brianstrange

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Nov 22, 2011
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Trim the return line to 1" above the tank bottom. Also, measure from the bottom of the tank to the mounting deck, and match those measurements with the bottom of the strainer to the hanger gasket by trimming the rubber pump supply line, and clamping them to their ports. The idea here is for the strainer to gently rest on the bottom of the fuel tank. The pump gets wire tied to the return tube. I like to insulate the two with fuel line on return tube. Just push it up to the point where pump meets the tube. Adjust the strainer so it points to the drivers side of the tank. You also want to connect the power and ground wires from the hanger bulkhead to the pump. Use care to make good connections as the last thing you want to do is drop your tank for a bad connection.
 

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brianstrange

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Nov 22, 2011
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This is the pump hanger installed. It's not screwed in yet because I'm allowing the sealant to dry the "C" ring to the under side of the tank. Always remember that it's there (document) so that you don't drop the ring into the tank when servicing.

I hope this helps someone out, as this forum has been very good to me so far.
 

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lonesouth

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Dec 18, 2003
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5,045
damnit man...that's a worse cliff hanger than LOST ever gave us!

Oh, and the stock pickup would be a good place to plumb the line from the other tank if you are going to use a transfer pump to fill the main from the Aux...
 
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brianstrange

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Nov 22, 2011
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1,626
damnit man...that's a worse cliff hanger than LOST ever gave us!

Oh, and the stock pickup would be a good place to plumb the line from the other tank if you are going to use a transfer pump to fill the main from the Aux...

The pump hanger has a provision for send, return, and vent with a built in rollover valve)
 

blazinchuck

Bronco Guru
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Jul 14, 2005
Messages
3,319
im wondering if this possible for the aftermarket steel tanks? but instead of using the C plate...maybe thread the holes on the top of the tank? very nice mod BTW!!!

curious, what happens once the hanger is mounted and you have to replace a pump, as soon as you loosen the screws will the the C plate drop because you cant get access to hold it? thanks again,Chuck
 
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brianstrange

Bronco Guru
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Nov 22, 2011
Messages
1,626
im wondering if this possible for the aftermarket steel tanks? but instead of using the C plate...maybe thread the holes on the top of the tank? very nice mod BTW!!!

curious, what happens once the hanger is mounted and you have to replace a pump, as soon as you loosen the screws will the the C plate drop because you cant get access to hold it? thanks again,Chuck

You can use this on a steel tank as well. I would still use the c ring, but just tack it in place. As far as the plastic tank, you could remove one screw, replace it with a very long screw, remove the rest, and place a small screw under. The silicone should hold it in place though.

One thing to note: Tanks Inc has a $250 in tank pump with a built in tray as well. With the Bronco tanks being flat, they would work well if there's the proper clearance below the rear tub.
 

blazinchuck

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Jul 14, 2005
Messages
3,319
very cool, i have a BCB tank(non efi pump)...but would like to do this mod. tired of 2 pumps now
 

blazinchuck

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Jul 14, 2005
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i guess a super easy answer would be to find sender/pump hanger that fit the same hole as what the sender is already lol
 
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brianstrange

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i guess a super easy answer would be to find sender/pump hanger that fit the same hole as what the sender is already lol

You could even strap a pump to the stock sender if you can find a way to fit electrical and fuel bulkheads
 

lonesouth

Contributor
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Dec 18, 2003
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I kinda want to put a GM fuel pump in mine, just because I like the sound
 

broncoitis

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Jul 23, 2010
Messages
4,449
Or you could just build you own tank altogether for a fraction of what they are charging at the vendors! Built mine and happy with it so far and no leaks.

Nice job on what you did with the conversion. My only question is what tank are you using becuase does not look like a Bronco tank to me? Side Tank?
 
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brianstrange

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Nov 22, 2011
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Or you could just build you own tank altogether for a fraction of what they are charging at the vendors! Built mine and happy with it so far and no leaks.

Nice job on what you did with the conversion. My only question is what tank are you using becuase does not look like a Bronco tank to me? Side Tank?

This write up is about in tank fuel pumps, not fuel tanks. Why would I build a tank when I already have a good one?

The tank pictured is the "1977 only" rear plastic tank, but the pump hanger will work in just about anything.
 

broncoitis

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Jul 23, 2010
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4,449
This write up is about in tank fuel pumps, not fuel tanks. Why would I build a tank when I already have a good one?

The tank pictured is the "1977 only" rear plastic tank, but the pump hanger will work in just about anything.

I understand what the writeup is about! I also understand that the Main tank on the bronco is pretty small for the most part. Prior to that I had never seen a 77 main tank but that is definitely a nice install with the in tank pump that was done. I would have considered it had I seen it.

Anyway, not tryin to hijack the thread or anything. Anything to improve the Bronco is good in my eyes! :cool:
 

Bronco_69

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Jun 14, 2001
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Loc.
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i guess a super easy answer would be to find sender/pump hanger that fit the same hole as what the sender is already lol

a foxbody mustang sender fits in the 75 bronco tank. all you have to do is put a 3/4" street elbow on the pump to angle the pick up down. then put the filter sock on the end of the elbow.

i have pics some where and i am about to do another one. i then ran factory EFI lines to my rails with a OEM style filter. ;D
 
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