Originally Posted by bdjuju
Can't recall if I've mentioned this earlier (it's been so long..) but I've been trying to solve the fuel pump issue as well, subject is a CB550-4. I really want to use a Suzuki in-tank pump & have a smashed up GSXR tank was planning on grafting the flange area into the bottom of the 550's tank at some point. Maybe some experimentation with a junk CL tank is in order?
The other trick may be to use a smaller 'surge tank', place the pump in that, somewhere in the 'triangle' area under the seat, and just feed it from the main tank.
I was considering the same idea, and had bought a CBR in-tank pump assembly to try to mock it up, but there just wasn't the cross-sectional area to fit the pump in the tank anywhere near the bottom. It would have required some major hacking & re-welding of the tank. Now, IIRC, the 550's tank is a bit wider, so you may be able to fit it, after adjusting where the pickup will sit and welding on a nice flange. This may be version 2 for me too, finding a larger tank that I can do that with, but for the moment I'm sticking with the external.
The triangle under the seat is already taken by a re-located battery box, relays, and the megasquirt itself, so the only empty real-estate I have is between and below the carbs over the transmission. Ive sat and stared at it for a number of nights trying to figure out where to put stuff so that it all fits, and trying to keep the high-current and high-voltage components away from sensitive electronics & fuel connections.