cutting hole for fuel pump installation in gas tank
Measuring the depth of a fuel tank
measuring and cutting fuel pump hanger bracket
cutting a fuel pump mounting bracket
measuring and cutting fuel pump foam baffle
cutting foam fuel pump baffle
drilling holes into a fuel tank for a fuel pump install
putting foam fuel baffle into a car gas tank
man installing a fuel pump into a gas tank
bolting a fuel pump into a gas tank
gas tank with fuel pump installed

Choose the best spot to mount your Phantom Fuel System and drill your 3.25” hole.

Measure the depth of the tank.

Measure the fuel pump hanger bracket. Bracket will be cut shorter than the depth of the tank.

Cut the bracket to length.

Measure foam baffle / basket. Foam will be 1″ taller than the depth of the tank.

Cut to length.

Using the guide holes on the installation tool, drill the holes for the studs that are already in place on the retainer ring.

Use the installation tool to guide the foam baffle / basket into the tank. Once in place, install the studded retainer ring into the tank as well.

Secure fuel pump to the hanger. Install gasket and fuel pump hanger assembly.

Tighten down using the nylon lock nuts and washers ensuring a tight seal all the way around.

Late model EFI engine swaps and aftermarket EFI systems are hot right now—and it’s no secret why. With the ample supply of parts and kits from the aftermarket, you can make ridiculous power and do it more affordably than ever with these conversions.

Until now, though, the fuel system has been a costly and time-consuming upgrade for these swaps. Block mount pumps aren’t an option on today’s engines, carbureted fuel pumps are not going to work with EFI, and the tanks in these cars are not designed for EFI pumps. The most realistic options have included installing a fuel cell, welding in a big sump on your tank, or fabricating a custom fuel tank. While all of these options will work, they can be very expensive, require a lot of work, and may just not be what you want.

Thankfully, Aeromotive has made things much easier now with the Phantom Fuel System.

We first showed you this system back in November at the SEMA Show. It’s a complete kit that gives you everything you need to install a fuel pump and baffle/basket into almost any fuel tank. The system is built around Aeromotive’s in-tank 340 Stealth Fuel Pump, which is capable of handling serious power even at EFI pressures. You also get a black anodized hanger assembly and an internal baffle to control fuel slosh and keep the fuel pump submerged. The best part, this entire system is modular and can be cut to height to fit almost any tank, including your stock tank.

Why In-Tank Is Better

By using an in-tank fuel pump, you virtually eliminate hot fuel handling issues like cavitation and vapor lock because the pump is constantly submerged, taking advantage of a column height of fuel on the inlet of the pump. And, because of the innovative baffle or basket, you can control fuel slosh and keep fuel at the pickup point (the pump) at all times—even with low fuel levels and in extreme driving conditions!

Aeromotive‘s Stealth Fuel Pump is capable of handling up to 700 horsepower from supercharged EFI applications or 1,000 horsepower from carbureted supercharged engines. You can switch between carbureted and EFI with nothing more than a regulator swap. You can also use your factory tank or a reproduction to maintain that stock look while enjoying the performance you demand.

So how hard is to install the Phantom system? Click on the slide show (photos courtesy of Aeromotive) above for a step-by-step installation.

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Author: David Fuller

David Fuller is OnAllCylinders' managing editor. During his 20-year career in the auto industry, he has covered a variety of races, shows, and industry events and has authored articles for multiple magazines. He has also partnered with mainstream and trade publications on a wide range of editorial projects. In 2012, he helped establish OnAllCylinders, where he enjoys covering all facets of hot rodding and racing.