Boyd Tank Installation

[pjmoreland]

I know this installation has been done a thousand times before, but I figured I'd share a bunch of photos from my installation of a Boyd rear-mounted tank. Installation of this tank was way more involved than I though it would be. In total, it took me about 40 hours to complete. I basically copied what 67C10Step did to his truck, shown in this thread:

https://67-72chevytrucks.com/vboard/...d.php?t=823041

I ordered the bed-fill version of the tank with the Aeromotive Stealth 340 pump. I have a carburetor, but I'm planning on going to fuel injection eventually, and I'm in the process of rebuilding a Vortec 880 L31 engine that has no provision for a mechanical fuel pump. I went with the 0-90 Ohm sender to work with my OE fuel gauge. I also got the rollover safety vent (I recommend not using this - see post #125) and the flush mount floor filler kit.

https://fueltankparts.com/collection...0-in-tank-pump

Like 67C10Step, I got a set of hard lines from sstubes.com. The part number is TGL7111OM, and it comes with both the supply and return lines. Each line comes in two pieces to make installation easier. By the way, they make a stainless version of this kit. I was planning on getting stainless, but it was out of stock at the time.

https://www.sstubes.com/products/tgl...line-kit-steel

The ends of these hard lines are flared to work with quick connect fittings, which requires conversion to flexible hoses at the tank and engine. Here's a complete list of the fittings I used:

Supply (3/8):
Vibrant 24902 - Tank pump to -6 AN hose
Russell 611203 - hose to hard line, rear
Russell 611203 - hard line to hose, front
Vibrant 26902 - hose to fuel pressure regulator

Return (5/16):
Vibrant 26902 - Tank return inlet to -6 AN hose
Russell 611250 - hose to hard line, rear (611253 = black version, out of stock)
Russell 611250 - hard line to hose, front
Vibrant 26902 - hose to fuel pressure regulator

Holley 12-881 - Fuel Pressure Regulator

Summit SUM-240603B - -6 AN hose, 3 feet (quantity 2 of these used)

I used an Edelbrock 81233 fuel line kit to go from the fuel pressure regulator up to an Edelbrock 8131 filter/line kit that attaches to my 1405 carb. I had to replace the lower fitting on the fuel line kit with one that had a 30 degree bend on it to avoid the lower radiator hose. I purchased a house brand fitting from a local supplier, but it is the same as Vibrant 21306.

I used the following clips from inlinetube.com to attach the hard lines and the rear brake line to the frame:

CLP133 - 3/8", 5/16" & 1/4" clip, quantity 5
CLP170 - 3/8" & 5/16" clip, quantity 3


For the electrical system, I used the following components:

Holley 12-810 - Oil pressure safety switch
Edelmann 227200 - Tee fitting for safety switch
Standard Motor Products FV7 - Pump cutoff switch
Bosch 332209150 - 30A relay
Bosch 3334485007 - Relay connector housing
TE 18304-2 - Crimp terminal for relay, 10-12awg, quantity 2
TE 42238-2 - Crimp terminal for relay, 14-18awg, quantity 2
Summit Racing SUM-87075R - 10awg wire, red, 75ft (used about 25ft)
Sierra Marine FS45470 - 30A fuse holder
Deutsch DT04-2P & DT06-2S - connector set for fuel sender
Muzzys WeatherPack 2-Pin 12-14awg - connector set for fuel pump

I also used various other small electrical items, such as short lengths of wire and ring terminals for ground and oil pressure switch connections, an ~18ft length of 16awg brown wire for the fuel level sender, and some Packard 56 crimp terminals for passing some wires through the firewall bulkhead connector.

Here's the rubber pad material I used between the tank and the frame rails:
https://www.mcmaster.com/8610K83/

EDIT - I now have a dummy filler neck to plug the hole in the cab for sale here:
http://67-72chevytrucks.com/vboard/s...29#post9027329

The tank installation process can be broken into these smaller categories, but there is a fair amount of jumping back and forth between them:

1) Fuel Tank Attachment
2) Fuel Line Installation
3) Electrical

One thing I should mention is that the Russell quick connect fittings had an extremely tight fit onto the hard lines. I ended up cleaning up the hard lines with 400-grit sand paper after the lines were installed. I also applied grease to the hard lines prior to installing the fittings. It would have been much easier to do this cleanup on the hard lines prior to installing them in the truck. I suggest making sure the Russell fittings slide onto the hard lines prior to installation of the hard lines.