I had my tank sealed recently, and looking at the baffle cup around the pickup/return, I believe there was an open gap at the bottom edge (circled in yellow) to allow gas to flow in/out of the cup. It looks like the sealer has closed this gap - just checking to see if anyone can confirm that this is the only open edge area of the cup. Thanks!

 

Upon further investigation, it looks like the only open areas between the main tank area and the pickup cup are the corners in the yellow circled area. Each corner has a raised "dimple" with a hole in it (picture attached). The good news in my case is that access under both corners is clear - if I feed a wire under the corners, I can see it through each hole. Unfortunately, there is a skin of the sealant over each hole which will need to be cut out somehow. I have a finer appreciation for surgeons who do arthroscopic surgery at this point ...

 

How is the patient doing? Seriously, though - I've never dug this far into my fuel tank, so I don't have much to offer except that you'll definitely want to be sure the cup allows free flow as a baffle smooths fuel around the pickup sock. The EFI system relies more on pump PRESSURE than volume, but without those holes open, once the tank gets below the top height of the cup, you'd have a problem.

 

Slow progress, took a couple of weeks to get the tank back after cleaning/sealing. Once I clean out the two cup holes, I should be good to reinstall the tank and get it running again. Hoping to get a few hundred miles on it before I have to put it away for the season. I will be removing the added filter between the tank and pump, and putting in a new filter in the OE location even though the one in there is only a year or so old, so I'll be back to the OE fuel line configuration. Flushed the fuel line while the tank was out, seemed clean and the fuel volume seemed reasonable so I don't suspect any line blockages or pump flow issues (which I'd hope not - new OE pump put in a year or so ago with the filter).

Also picked up two sets of OE injectors, and had them cleaned/tested. All four passed, but the flow test numbers didn't make sense to me as they were similar to the numbers I got from the non-OE green top injectors that I currently have installed. You had made a comment in another thread about the green top injectors flow rate being under OE spec, but I'm wondering now if we were looking at the wrong numbers. The green top test results showed ~107cc for 15 sec for the dynamic flow test and ~80cc for 5 sec for the static flow test. The math we did earlier was with the dynamic flow numbers, but I think that the OE spec of 680cc/min is for static flow? The tester indicated that the flow numbers need to be multiplied by 0.85 because of the test fluid he uses. Doing the math, the green top injectors have a static flow rate of ~816cc/min. The numbers I got back for the OE injectors were ~101cc for 15 sec for the dynamic test (similar numbers to the green top injectors), and the static rates were ~70cc for 5 sec. Doing the math on the OE injector static rates, I get a rate of ~714cc/min which seems reasonable based on what I've seen/read about the OE injectors.

I'm planning on running with the green top injectors currently installed, at least initially, and see if there are any further issues. It'll save me a little bit of time/effort not having to pull the DC off again, especially with time running short this driving season. I'll update progress in the other thread, seeing as this one should be closed once I open up the two tank cup holes.

 

On Fuel Injectors for SEs, nominal flow rate is 680cc/min. The problem occurs when guys try to install 2nd Gen injectors which they have 4 and are 580cc/min (idle and cruise) OR 800+cc/min (WOT) which are used as staged Fuel Injection. Neither of those low impedance Injectors will work with our SE.

I have no idea about the static flow rate or the 85% multiplier, as there's nothing in the intake restricting the free spray of fuel, in fact there's an ever so slight vacuum due to Bernoulli Principle when the intake is flowing, so maybe that's what they're trying to account for. At any rate (*pun), the flow report you posted looked fine, and it's far more important to have a clean spray pattern for them to run well - and not leak.

Let us know how it goes,

 

Opened up the two cup holes today - tough access doing it through the pickup tube hole. Put a gallon or so of gas in the tank, sloshed it back and forth and verified fuel flow in/out of the cup, so I think I'm all set. Got everything put back together - when I emptied the old filter (the OE one after the pump), there was a bunch of sediment that came out so I'm hopeful that the tank sealing will solve the issue. First road test tomorrow - fingers crossed.