Today I was thinking about the fuel baffle and how it was built so it would go through the hole in the tank. That got me thinking, why didn't they just make it smaller? Hervey's set up drops straight into the tank with a little compression. I can't see the original baffle having any more useful fuel holding capacity than Hervey's (if it had a solid base with smaller holes) on a low tank except for its location. What if an updated baffle was built with a smaller yet deeper baffle that had an extension to put it in the location of the old baffle?
I have Hervey's baffle system in my D. I live in a flat area and don't run my tank less than half empty because of my broken fuel sender so I've not had any issue. When I took my old baffle out the bottom was missing so even if I need to put mine back in it would be useless.