Modifying a stock plastic gas tank
Your best bet would either be one of the ready to drop in aluminum tanks that Speed Inc. sells, or to get a steel '98 tank and add a sump to it.
I've been very happy with my homemade sump in my stock '98 tank.
You can heat-weld some poly (with the right
heat gun and filler). Solvent welding is
out of the question (duh). Using a 2-piece
compression bulkhead fitting with solvent-resistant rubber seal and enough mechanical
overlap to avoid compromising the limited
strength of the tank might be reliable.
Finding such a fitting is doubtful but to
make one out of stainless washers and SS
fitting hardware is simple if you have a
MIG, TIG or even OA brazing available. You
might check around for AN bulkhead fittings,
as these might have some application in
chemical tanks, etc. where plastic tank
meets stainless line. As for the seal, I
dunno.
If you're not hung up on having AN fittings,
might look for something in brass. Not like
the tank sees high pressure.




