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Understood Lee.

IMO the remaining risk areas here are how well the nitrile-impregnated gasket and the wiring pass-through tolerate exposure to liquid fuel over time. Both are engineered for a top-tank installation. We'll see.

I suppose I've volunteered to be the guy that finds out.

Max

No leaks overnight. I used the pump to empty the tank and installed it in the car.

It's 20 degrees out and snowing. When my feet warm up I'll go back out and power the pump up and make sure it makes pressure.

Side note: After pumping out the tank, there wasn't more than a dribble left. That mat really works. Max

Success. A little noisier than I expected but it shouldn't be audible over the engine sound.
Max

So ... my clamped-hose strategy didn't work too well. As soon as I drove around the yard the tie-rod knocked the outside hose off. It was sticking out about 40mm from the bulkhead. Too far as it happens.
New approach: This has a stickout of only 25mm.
Plumbing got cleaner too.
Max

For anyone still here I would like to cap this thread off. The car has now been driven some and I got a 158 mile trip in last week. The only issue I've had was a slight fuel seep where the wires come through that pass-through. I solved that with epoxy. The gasket is holding up just fine.

One annoyance is the sound of the pump. It's louder than I like and I will probably go back in and add some sound insulating material to the mount.

All in all I'm claiming success for this experiment. If I do this again (on my KG) I will pay closer attention to where the fuel lines exit the tunnel so they aren't close to the tie-rod.

Max Welton

Glad you are finally able to call the job complete and fully functioning. Well done!