Here are some pics of my new fuel system I started working on today. Things are not complete yet but I figured I'd post some pics anyway.

Modified stock fuel pump housing, -8AN feed line and -6AN return line w/ Walbro 255lph in-tank pump


Additional Walbro 255lph in-line fuel pump


Aeromotive in-line fuel filter and fuel pressure regulator

Looks like you put some good work into it. What are your goals for the car?

The car should be in the neighorhood of 600awhp.

11 sec gsx, can you do a write up on this? I want to do the same thing with my car in the next month. I can make all the hoses no problem but, whatever you can provide for us would be much appreciated. That system looks awsome. Great job!

To be completely honest I don't know if I really have the time to do a detailed write-up on this. Plus I didn't take any other pictures other than what I already posted. However, if you have any specific questions or need part numbers for certain fittings I will do my best to help you out.

wait, so your using two 255 pumps and an aeromotive inline pump? what are you trying to do? run your car off of water pressure?

tstkl said:

wait, so your using two 255 pumps and an aeromotive inline pump? what are you trying to do? run your car off of water pressure?

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read.

Aeromotive in line fuel filter.. not pump.

drivemusicnow said:

read.

Aeromotive in line fuel filter.. not pump.

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No, he stated he has one in the tank and one inline to, you read.

11sec_GSX said:

To be completely honest I don't know if I really have the time to do a detailed write-up on this. Plus I didn't take any other pictures other than what I already posted. However, if you have any specific questions or need part numbers for certain fittings I will do my best to help you out.

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I guess the only thing I need to know is what you used to get the fuel in and out of the tank. Now what I mean is - what fitting did you use to get the fuel to the -8 feed line and what style for the return. Like I said - the lines are no problem. But, anything to show how to modify the fuel tank cap - please share.

howie3 said:

No, he stated he has one in the tank and one inline to, you read.

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drivemusic now has it right. You guys there is one (1) Walbro 255 pump in the tank and one (1) Walbro 255 pump in-line. There is only two (2) pumps. The is no Aeromotive pump. And I only have one (1) Aeromotive in-line fuel FILTER.

hopwoodp said:

I guess the only thing I need to know is what you used to get the fuel in and out of the tank. Now what I mean is - what fitting did you use to get the fuel to the -8 feed line and what style for the return. Like I said - the lines are no problem. But, anything to show how to modify the fuel tank cap - please share.

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OK modifiying the stock fuel pump assembly took by far the most work. I will try my best to explain what I did without pictures. Depending on whteher you plan to keep your back seats or not there are a few different ways you can do this. I personally chose to keep my back seats in the car. So the tubing coming out of the top of the housing for the feed line needed to have a tight radius bend in order to keep it low enough so that the cover and back seats could go back in. This proved to be somewhat hard to do without bending the tubing, even with a tubing bender because of the tight radius I needed and the size of the tubing, (1/2").

So here we go....I re-used the original vent location, fitting and hose. I re-located the return line. I cut off the original return line fitting as close to the top of the housing as I could and then used a drill to drill the rest of it down otothe top of the housing. The drill worked really nice for removing the rest of the material. I then JB welded the hole closed. I then drilled a 1/2" hole for the return line in it's new location (seen in the pic). I used a -6AN 90 degree bulkhead fitting which will fit into the 1/2" hole. Actually you may have to enlarge the hole just a tad but a 1/2" drill was the biggest size I had. You will need to use a -6AN jam nut on the bulkhead on the top of the housing to get you up high enough to clear the white plastic piece that screws the housing onto your tank. I used two (2) -6AN jam nuts on the bottom side of the bulkhead. That takes care of the return line.

Now on to the feed line. I used the original feed location, but just like I did for the original return line, I cut off the fitting as close to the housing as possible and then used a drill to drill down and remove the rest of the material until I got to the top of the housing. Tricky part about the feed line is I wanted to re-use the original mouting location for the pump so I had to re-use the tube that is welded to the underside of the housing where the fuel pump outlet slides into and seals with an o-ring. So what I did was drill a 1/2" hole right down through the original feed location. That tube piece is going to fall out. Don't lose it as you will need it. I then bolted the fuel pump up into place with this piece of tube pushed onto the fuel pump outlet. The pump bolts onto the housing bracket at the bottom. The top of the pump will be free as it is currently attached to nothing. This is where you will have to bend a piece of 1/2" aluminum tubing and push it down through the 1/2" hole and onto the top of the tube piece attached to the fuel pump outlet. By doing it this way you know the pump is in the proper stock mounting location. You will then need to JB weld the 1/2" tubing to the tubing piece on the top of the fuel pump outelt and JB weld the tubing to the the housing on both sides. I would let it sit for at at least 24 hours before installing it back in the tank. For extra security I even zip-tied the pump to the bracket.

Here is a list of some of the part numbers from Summit Racing that I used.....

-Earls -6AN jam nuts EAR-592406ERL
-Earls -6AN 90 degree bulkhead EAR-983306ERL
-Earls -8AN to 1/2" tubing adapter EAR-165008ERL
-Summit 1/2" tubing 25ft. SUM-G2512

Once the housing was back in the tank I had to cut away some of the sheet metal to make room to attach the hose ends to the fittings on the housing. I used a -6AN straight hose end on the return line fitting and a 45 degree fitting for the feed line. I tried using a -8AN straight hose end but it was very hard to get bent up and into position. I could have done it but I felt it was going to be putting a lot of stress on the aluminum tubing which was only JB welded into place to I went with the 45 degree fitting which was much easier to get into position and it also doesn't put any stress on the tubing....Wow, I'm sure that wasn't the easiest to follow without pictures to help visualize things but if you need anything else let me know.

Awsome, that was just about all I need to do this. I am sure I can find all this parts at work. Thanks for the help!! =)

That looks nice man, what are your goals for the car that require -8 lines???
Are you going to put a metal skid plate or anything on the pump under the car?

good stuff. looks good.

Looks good. I dunno bout the jbweld though. that stuffs mean (used it for a valve seat in a lawn tractor), but i don't know if i'd trust it with gas. i have seen people put a bulkhead in there for the outlet and put a hosebarb on the other end and a little piece of hose down to the pump. it really is a pisser that there isn't anygood way to plumb the fuelsystem on these unless you run an external pump.

Yeah, ideally I did not want to have to use the JB weld, however I do believe it will hold up just fine. I originally ordered a bulkhead, and hose barb fitting and was going to do it exactly the way you explained, but in order to use the factory mounting braket I had to keep the fuel pump in the exact same mounting location and this was the only way to do it. With the bulkhead and barb fitting the fuel pump would have sit like 2 inches lower and I don't think it would have fit in the tank then anyway as it's already right at the bottom as it is. I think it's going to work great, I have no doubts.

That's an amazing setup! I really like it. Out of curiosity, and you don't have to answer if you don't want to, but about how much do you think that fuel system cost you? The only fuel mods I've done are a 190lph pump, but I'm always trying to plan ahead.

cool, keep an eye on the jbweld and let us know how it holds up. Are you runnin the two fuel pumps inline? any reasons whe you chose that over a single large pump?

A lot of stock manufacturers run dual pumps, one in tank and another inline. I believe it isn't to flow more, but it is to keep everything more free flowing, which essentially reduces strain from each fuel pump.

Did you use any type of surge tank for the inline fuel pump or do you have it setup from the tank to the inline, inline to rail? Is your fuel filter before or after the fuel rail?

drivemusicnow said:

read.

Aeromotive in line fuel filter.. not pump.

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thanks, my bad

cool, keep an eye on the jbweld and let us know how it holds up. Are you runnin the two fuel pumps inline? any reasons whe you chose that over a single large pump?

bastarddsm said:

cool, keep an eye on the jbweld and let us know how it holds up. Are you runnin the two fuel pumps inline? any reasons whe you chose that over a single large pump?

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I have one fuel pump in-tank and one in-line. Both pumps are triggered by the ECU and run constantly. I chose this setup over a large single pump because the car is street driven. I didn't want to have to install a fuel cell and a lot people burn up the large external pumps on street driven cars. Big externals are more of a track only pump in my opinion.

MaNGiNa24 said:

Did you use any type of surge tank for the inline fuel pump or do you have it setup from the tank to the inline, inline to rail? Is your fuel filter before or after the fuel rail?

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There is no type of surge tank. The in-tank pump feeds the in-line pump which then goes to the rail but not before passing through the fuel filter, so yes the filter is before the rail.

So one thing I've always wondered about the fuel pump assembly. If you upgrade all the lines without changing the fuel pump assembly lines, does it actually do any good since it is being restricted so much?

justin0469 said:

So one thing I've always wondered about the fuel pump assembly. If you upgrade all the lines without changing the fuel pump assembly lines, does it actually do any good since it is being restricted so much?

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My fuel pump assembly lines are upgraded. Everything from the fuel pump outlet to the fuel rail is -8AN. However if you are not referring the me specifically and asking a general question, even upgrading just the line from the stock fuel filter to the rail will make a significant difference. The biggest restriction in the stock fuel system is the banjo fitting on the fuel filter.