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My Walbro 450 fuel pump install and modified sender

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Stock 2g sending unit with a 450 lph Walbro e85 pump.

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Stock like are going to be more then enough for the average person on here. In my VERY Honest opinion, anyone looking to upgrade their lines I'd skip over -6an and go -8an.
Crunch the numbers. You'd be surprised. None of us truely flow that much fuel in these cars.

Take a Wally 450 flowing no more than 2 GPM. To achieve a velocity of 13 ft/sec (which is right in the middle of the range that you want to be in), you only need 1/4" I.D fuel line. That means -4AN is almost large enough. Granted, pressure drop would suck with it. So, we move up to -6AN. At the same 2GMP flowrate, velocity drops to 5-6 ft/sec and pressure drop is less than 5 psi. IMO, this is a pretty decent size for this flowrate.

Somewhere around four Walbro 450's is where you'd need -8 AN hose. To run one of these pump with -8 line will simply give close to zero pressure drop and a slow velocity of around 3 ft/sec. Nothing much to gain by skipping right to -8 for such a small rate of fuel flow. As mentioned, -6 is large enough for most people.
 
^i would have used a metal hose
Clamp. That zip tie will not be there after you expose it to e85

Here's my full blown unit I pulled out after being exposed to e85 since 2009. All zip ties are in tact. Please don't post false information.

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Here's my full blown unit I pulled out after being exposed to e85 since 2009. All zip ties are in tact. Please don't post false information.



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Where are your zip ties? You ised a hose clamp around your pump. He used a plastic zip tie.

E85 is corrosive. If itll eat copper and solder itll eat cheap plastic.

I'm not saying itll happen instantly like with acetone, but it will happen eventually, and then your pump is hanging by its wires.
 
None the less if they recommend ss filters and such I'd be sketxhed about that, butnto each their own
The reason why SS filters are recommended over paper for E85 has much less to do with corrosion and more to do with maintainence and flow restriction. Paper elements will clog fairly quickly. So unless you're willing to change the element quite often, it's better to run a coarser element. And being that paper doesn't make for a good material for a coarse element, then make them with steel mesh. More specifically, stainless steel mesh due to it's anti-corrosive properties. The other benefit is that a coarse, SS element can be cleaned and reused.
 
So e85 isnt corrosive to plastic and rubber thrn? Why do they recommend sealed electronics for the 450? Seems thats the only real difference aside the extra 50lph in comparison to the 400

Ive honestly never ran e85 but ive seen what toluene does to plastic/rubber.
 
Sender fitting being constructed. Bothe pieces are stainless steel
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Fitting welded and trimmed
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Sender drilled
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Fitting welded in sender and glass beaded
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Prettied up
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Plug added back in. Proposed fittings added. Looking for a more low profile option.
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I'm also wondering if the pump sitting lower than stock is going to be an issue?
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Very nicely done! I am a craftsman I see that you have an eye for detail. again very nice job! I think you can build furniture check out what I am saying this is my profile on hgtv Sign In to HGTV not everyone has a steady hand;) Very good job!
 
Bostonhatcher - was the install very hard for the 450 pump on the stock 2g sending unit? Looks like it was straight forward other than splicing some wiring. What wires did you splice into for the pumps connector?

It's pretty straight forward but make sure you really think about the location of where you weld the an fittings on.

Yesterday my car wouldn't start. 0 psi on my fp gauge on my a-pillar. Found that the fuel sending unit connector can't handle the ~25 amps that the walbro 450 uses. This was after a couple months of use.

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Going with this solution:

McMaster-Carr
 
Can anyone beat this? I think I may have set a record

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It's pretty straight forward but make sure you really think about the location of where you weld the an fittings on.

Yesterday my car wouldn't start. 0 psi on my fp gauge on my a-pillar. Found that the fuel sending unit connector can't handle the ~25 amps that the walbro 450 uses. This was after a couple months of use.

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Going with this solution:

McMaster-Carr



Luckily I dont gave to worry about where I weld the AN bung at because I bought a modified -8an 2g awd sending unit with a wally 450 already installed for $200 :thumb:....

Did you have a fuel pump rewire and relay going back to your stock plug to keep the connector from getting too hot? I would think the fuel pump rewire relay would keep the connector from melting like that
 
Luckily I dont gave to worry about where I weld the AN bung at because I bought a modified -8an 2g awd sending unit with a wally 450 already installed for $200 :thumb:....

Did you have a fuel pump rewire and relay going back to your stock plug to keep the connector from getting too hot? I would think the fuel pump rewire relay would keep the connector from melting like that

I did not. It was hard wired. I would think the rewire would make it run even hotter. Pump has set resistance. More voltage = more amps = more heat.
 
Call me crazy but I may try to reuse the melted connector. It's just the fuel pump power pin hole that is melted which I won't be using. I really don't want to track down another one. Does anyone know the connector part #? If I can find it off newunitedracetech.com I'll order it.
 
I did not. It was hard wired. I would think the rewire would make it run even hotter. Pump has set resistance. More voltage = more amps = more heat.
This is actually incorrect. More voltage=less amperage. Voltage and amperage have inverse relationships. That's why high draw devices such as air compressors, ovens, etc use 220v to reduce draw by about half.
 
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