Other random notes:
The fuel filter 'sock' is actually, by chance, an OE replacement for this vehicle.
The pickup tube ended up being 3/8 because it's more common and it was easier to find a fitting that adapted 3/8 tube to 5/16 hose than to add a second adapter in the hose. The pump has no problem priming the 3/8 tube.
Most of the fittings did not come with the accompanying washers, nuts, flare nut, etc.
It was cheaper to buy a 37-degree -AN flare tool than it was to have somebody make two flares for me.
The fuel sock is supposed to have some kind of fastener but I just put a slight flare on the end of the pickup tube and forced it into the sock female. it felt like a good seal and it primed right up.
a Rotozip bit in a cordless drill cut the sender and fill holes very well. I saved the cut-outs for filler material in case I need to do any plastic welding.
I leak tested the tank with a garden sprayer tank and plumbing leak test 'soap bubbles' spray. I had 2 leaks: first was at the top of the fill tube (wasn't pushed on far enough/clamp was crooked) The second was at the top *bolt* of the fill flange. I added a touch of Seal-All and re-installed that bolt.
I re-used 2 of the 4 separators from the stock tank. I followed basic rules for vapor lines: tapped the tank as high as possible, all lines run down-hill towards the tank, ran a long run before the separators to reduce the amount of fuel that may slosh toward the separator, separators are higher than the top of the tank. I ran fuel line to the first separator and vapor line between them and to the vapor check valve.
The sender is a floating arm style. I had to run it towards a corner to fit it in the smaller 12gl tank. I had to run a seperate ground wire from one of the sender's mounting screws so the sender/gauge circuit would complete.
There is more ground clearance than ever and there is ample room to run my 2.5" exhaust essentially straight out the back. (only curve will be to go over the axle.)
The skidplate/outer shell is made from an old aluminum constuction sign. I'll bend it into a box shape, then maybe have the corners TIG welded. Or I'll buy the right gas and try to run aluminum wire through my MIG welder.
Yes, the body is terribly rusted in the back. I'll address that next, but I wanted to stop leaking/smelling gasoline first. Also it was soooo nice to be able to top off the tank for the first time in about a year. Can't wait to check the mpg!