Gas Tank
I took the fuel pump assembly out of the 240sx tank, cut out the mounting flange from the top of the tank and removed the baffle cup from the bottom of the tank. The 510 tank doesn't have much in the way of baffles to keep fuel around an internal pump so I figured the 240SX cup would help a great deal.
A hole was cut into the top of the 510 tank for the mounting flange and the stock fuel lines and fuel level sender were cut out. Since the original vent for the tank was in the center (from a '69) and was cut out, a new one was soldered on on the drivers side of the tank.
The baffle cup was tacked into place and all the holes were welded shut. The original paint was stripped and the exterior of the tank was repainted with zero-rust.
The 510 tank I used had been sitting for around 17 years with gas in the tank. I used Por-15 Marine Clean to clean out the tank and then sealed the inside with Por-15 U.S. Standard Fuel Tank Sealer.
The fuel pump assembly was cleaned up and painted. It was also fitted with a Walbro HP 255LPH pump. Since I decided to use the 240SX fuel level sender I extended the arm so that it would register the full range in the 510 tank. Part of the stock baffling in the tank had to be removed to accommodate the float arm. A new tank o-ring was installed and the fuel pump assembly was bolted back in with new Nissan bolts.
