I think I had my last 240 under control. Following the "internet common knowledge guide to building POS 240s" was one of the big problems.
- When you do a fuel pump, the gas tank seal is a mandatory replaceable item. No one ever does that. The FSM says that you have to. Buy a real pump kit like a Tomei and it'll be included.
- Cars without catalytic converters smell like fuel. No one ever runs a cat. Even NA cars with good tunes smell. I'm finding this complaint even on stock 350Z's with test pipes.
- Cars with cats and are out of tune smell like fuel. YMMV.
- The first thing people do is delete the charcoal canister, all the lines, and the solenoids. That's what keeps vapor pressure from building up in your tank. That high pressure turns everything into a leak. Ever release the gas cap and it sounds like a million psi escaping... yeah.
- Don't forget that there are more rubber lines under the car in the rear. People change the engine bay lines due to age, but the same 20 year old ones are still dragging along in the rear.
- Not having AC, isn't helping. There is a piece that I don't know the name of in the rear that vents air from inside the car. It's not supposed to let air in from the outside, but I'd be willing to bet that over time it doesn't seal well. Combine that with driving with the windows down creating a bit of vacuum, and you'd be drawing air directly from the gas tank area outside the car.
- Fuel smell is strong. It doesn't take much at all to notice. Even the smallest leak or being a bit too rich will do it.