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How to Build a Surge Tank

Contributed by: SDSEFI

To convert some carbureted vehicles to EFI, we recommend fitting a fuel surge tank to avoid fuel feed problems, especially during hard cornering. This is also useful on many stock EFI cars which have poorly baffled tanks. The surge tank stores a small amount of fuel for the high pressure pump to pick up if flow from the main tank is interrupted for any reason. Usually the tank is mounted in the engine compartment. Fuel is piped to it by either a stock engine driven mechanical pump or a low pressure electric pump. Often the stock electric pump can be used. A high pressure EFI pump will be mounted below the surge tank. The fuel gravity feeds into this pump and goes to the fuel rail. Fuel not used by the engine is returned from the rail, through the fuel pressure regulator, to the top of the surge tank. From here, if the surge tank is full, fuel is returned back to the main fuel tank. The schematic below shows a common setup: (click for larger image)

Most tanks will have three fittings on the top, one for feed from the low pressure pump, one for fuel returned through the fuel pressure regulator and one for the return back to the main fuel tank. Usually only one fitting is used on the bottom of the tank for feeding the high pressure pump. Tanks are usually about .5 to 1 liter in capacity, made from either steel or aluminum tubing. The tubing is usually 2.5 or 3 inch diameter and .050 to .075 wall thickness. A long tank allows any trapped air to rise to the top so it does not enter the high pressure pump. Threaded bosses are welded to the top and bottom caps or sides as in the example below. Usually 1/8 NPT or 1/4 NPT fittings are used but AN type fittings can also be used depending on your plumbing preferences.

This tank has 3 lower fittings for twin pumps plus a drain fitting. Earls NPT weld-in bosses are used. This tank is made from 3 inch, 6061 T6 tubing. Mild steel exhaust tubing also works well. All joints are carefully TIG welded. Test for leaks before installing.

Here are some Pre-made examples that are competatively priced:

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Reading Spark Plugs	Camshaft Understanding	Engine Timing	Intake Runner Length	Exhaust Flow Tuning	Camshaft Timing	Engine Cooling Basics	Compression Testing	Forced Induction
Tuning A/F Ratio Basics	Intake Manifold Basics	A look at cooling mods	Camber Caster Basics	Sequential Vs Batch Injection	Fuel Pressure Regulator	EGT Vs A/F EFI Tuning	Engine Start Programming	What is a fuel Injector?
Brush vs Brushless Motors	4-stroke motor diagram	Crankshafts Basics	Automotive Relays	EFI Tuning Basic Thoery Guide	Understanding Electric Motors	Water Meth Injection	Intercooler Basics	e85 Basics
Water to Air Intercooling	Turbo Surge	EFI Air Intake Temp Tuning	Map vs. MAF Sensor EFI Tuning	Engine Start up tuning for EFI Cars	Building an EFI Surge Tank	Intercooler Efficency	Boost Controllers	Engine Oil Weights
Exhaust Cutout Basics	Cold Air Intake vs Short Ram	Engine HP and Torque Basics	Intercooler Sprayer Basics	Turbo Manifold Design Basics	Cryo Liquid Co2 Cooling	Oil Cooler Basics and Installation	Boost by Gear Tuning	Closed Loop vs Open Loop O2 tuning
Changing your own oil	Static Vs. Dynamic Compression	Air to Air Vs. Water to Air Intercoolers	Vented vs Recirculating Blow Off Valves	Engine Intake Exhaust Valves	Wiring a fuel pump relay	Synthetic vs Regular Oil	O2 Sensor Repair Fix	Embrace the TURBO LAG

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