You don't need the nipple or adapter fitting on the pump bulkhead. On mine I reamed out the inside of the bulkhead fitting so the pump would slide in snugly.

LTUSPE said:

You don't need the nipple or adapter fitting on the pump bulkhead. On mine I reamed out the inside of the bulkhead fitting so the pump would slide in snugly.

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You just reamed it to the right diameter and put the walbro with the stock o-ring ?

How about the return line ? I'm thinking of fabbing a tube to fit back in the stock plastic siphon drilling it out to 1/8" ID ...

DSM4LIFE-AWD said:

You just reamed it to the right diameter and put the walbro with the stock o-ring ?

How about the return line ? I'm thinking of fabbing a tube to fit back in the stock plastic siphon drilling it out to 1/8" ID ...

Click to expand...

Right, I opened up the inside of the bulkhead to tightly fit around the walbro o-ring. The sides of the bulkhead seem to get a little thin but it's fine.


I left the return line as stock (there is really no need to change it). I did open up the siphon/venturi hole a bit to help with over-running the afpr.

Well I don't have any reamer at my shop ...

Just got all the drill size you can imagine but the finish in the hole will not be quite soft with a drill ... Really need to find a reamer asap.

DSM4LIFE-AWD said:

Well I don't have any reamer at my shop ...

Just got any drill you can imagine but the finish on the hole will not be quite soft with a drill ... Really need to find a reamer asap.

Click to expand...

A drill bit will work fine. I used a unibit to start (to help keep the bit from walking) then finished with a regular drill bit. I don't remember the size I used; just go a hair bigger than the pump outlet.

Still need to find a way to connect back my return line to the sihon ...

So no one want to help me ? No one before me as ever done this ? I don't think so ...

Well it just makes me want to keep secret what I'll do for the return line ...

I'm bringing this back alive. I've been looking around, and can't find anybody off hand who has done this bulkhead to the return line. DSM4LIFE, did you ever figure out how to hook it back up to the siphon? I know I've seen Paul Volk's return where he just welded the AN fitting on the top of the assembly, which is an option, but I happen to already have a -6 AN bulkhead for a return line and would like to use it if possible.

Would you think it is possible to cut the hard line coming out of the siphon and get a hose barb fitting on the bottom of the bulkhead and connect the two with a piece of fuel line? I know I should just go try it, but my car is in storage right now and I thought I'd ask here first.

another question on this subject is..
when is it necessary to change the return line?
I'v read that the return lines are insufficient on the 2g awd cars and cannot divert enough fuel at idle and low throttle after upgrading the pump.
building a 99 gsx this summer so i need to get it right.
fuel system will include:
walbro 255hp
aeromotive a1000 fpr
580cc injs for now most likely 750 or 850s in the future
will this overrun the fpr?