I'm going to say that over time that junk settled onto the bottom of the tank, with not enough going into the system to stop/plug it. So it went unnoticed. Then drawing the tank dry changes the whole dynamics of the flow at the bottom of the tank, and the junk starts to pull loose. I imagine it's something like that, that's JD's problem. As someone below said about a small bottle cap(I think) I had a similar issue with one of those little pieces that comes out of a small bottle cap. It apparently floated/moved around in my tank for a long time, until the fuel got low enough, then it would suck right over the outlet, and kill the engine. BUT, it was a real bugger finding it, because as soon as the engine quit, the draw on the fuel line quit, and that blasted piece would float back off, and I could get the engine running again! It was only because someone gave me the idea of the piece being in there, AND, I was able to look in the tank and eventually see it, that I ever figured it out.
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