New Fuel System Pics

[larsrya8]

Just making sure, the return line doesn't actually connect to anything on the tank side of the fuel pump assembly, just pours out into the tank?

The 2G FWD Walbro install VFAQ shows that the return line runs to the fuel pump assembly and pours out next to the pump.

Maybe I'm not understanding your question... so hopefully the pictures will help.

 

[Gamble97]

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.

I bent my stock line that goes into the fuel pump, and I have the SBR SS -6an fuel line.
So what will I need to replace that stock hard line w/ some of earl's fittings?
I was going through your list, but do I need the -8an fitting? I guess I just need more pics or someone to explain it better.
Thanks

 

[hopwoodp]

Look at some on my profile. This should help. 11sec_GSX also has some good ones on his profile. I have a -8 outlet from the fuel pump. It was alot easier that way imo.

 

[Gamble97]

Why use the -8an out when the rest of the system is a 6an?
This is what I don't understand

 

[Gamble97]

So what did 11sec_gsx use the blue L shapped fitting for?

 

[hopwoodp]

Why use the -8an out when the rest of the system is a 6an?
This is what I don't understand

The only reason I used a -8 feed was so I don't need to upgrade for a long long time. My whole feed is a -8 and return is a -6. This is only for personal preference. But, I you want to, you could upgrade to a -8 from the pump then step down to a -6 with a reducer fitting. It shouldn't hurt anything.

 

[justin0469]

So what did 11sec_gsx use the blue L shapped fitting for?

It is to dump returned fuel back into the tank.

 

[Gamble97]

The only reason I used a -8 feed was so I don't need to upgrade for a long long time. My whole feed is a -8 and return is a -6. This is only for personal preference. But, I you want to, you could upgrade to a -8 from the pump then step down to a -6 with a reducer fitting. It shouldn't hurt anything.

I was looking on summit, and I can't find a -6an to 1/2 tubing adapter. hmm.
Also, how do you get the aluminum tubing to stay in the top of the fuel pump w/o leaking?

 

[hopwoodp]

I was looking on summit, and I can't find a -6an to 1/2 tubing adapter. hmm.
Also, how do you get the aluminum tubing to stay in the top of the fuel pump w/o leaking?

Gamble97, you don't need a -6 to 1/2 tubing adapter - it is or should be AN as well(that is if you are fabbing up your own stuff). Now for the tubing I had mine welded to the housing. But, before you do that(if upgrading to a size -8 from the pump itself) you need to cut off the stock tube and drill it out and also cut off the fitting that the pump fits into and weld that onto the pipe. That is why I used steel for that.

 

[justin0469]

I was looking on summit, and I can't find a -6an to 1/2 tubing adapter. hmm.
Also, how do you get the aluminum tubing to stay in the top of the fuel pump w/o leaking?

If you plan on doing a -6AN feed line, you need to get 3/8" tubing and a -6AN to 3/8" tubing adapter instead of 1/2" tubing and adapter.

 

[Gamble97]

Ok, here's where I'm at. I took the fuel pump out and took off the stock line. I noticed that the feed goes directly into the pump..DUH!, but the line gets thicker before it connects to the pump. This thick end, I cut off and grinded it down, should I use this back on the pump or is there will the 3/8" tubing go directly to the top of the walbro pump?

 

[hopwoodp]

Ok, here's where I'm at. I took the fuel pump out and took off the stock line. I noticed that the feed goes directly into the pump..DUH!, but the line gets thicker before it connects to the pump. This thick end, I cut off and grinded it down, should I use this back on the pump or is there will the 3/8" tubing go directly to the top of the walbro pump?

Ok. Keep the stock piece that the pump goes into. The tube that you made will go into that stock piece. You are going to need to either drill or grind out the top of the fitting for the tube to fit into and get it welded. Then weld the tube to the pump housing like it was before. And don't try to use the tube to go over the pump.

 

[Gamble97]

Well I went to the store and they didn't have any -6 an to 3/8 tubing so I bougth 1/2" tubing with an -8an to 1/2" fitting. then I did a -8an to -6an step down.

I tried putting the tubing on the 1/2 and it just doesn't seem to stay on tight, I can pull it off easily. Is the brass ring in there a crush ring? I didn't want to crank on it too tight.

Ok, so I will take the thick piece from the stock line and drill it out to be 1/2" for my tubing. Then I will put my 1/2" tubing on there and weld it. Then I'll drill out the top of the fuel pump pump so that 1/2" tube will fit and weld it on. Put the compression fitting on and i'm done.
Is this all correct?
I've never welded before, so I'll see if my dad can do this for me. What type of welder is best to use?

What do you mean, not to use the tube to go over the pump? Not to be longer than the stocker?

I will be sure to take plenty of pics and try and find a place to host them so everyone on the board will be sure to know how to do this.

 

[hopwoodp]

Well I went to the store and they didn't have any -6 an to 3/8 tubing so I bougth 1/2" tubing with an -8an to 1/2" fitting. then I did a -8an to -6an step down.

I tried putting the tubing on the 1/2 and it just doesn't seem to stay on tight, I can pull it off easily. Is the brass ring in there a crush ring? I didn't want to crank on it too tight.

Ok, so I will take the thick piece from the stock line and drill it out to be 1/2" for my tubing. Then I will put my 1/2" tubing on there and weld it. Then I'll drill out the top of the fuel pump pump so that 1/2" tube will fit and weld it on. Put the compression fitting on and i'm done.
Is this all correct?
I've never welded before, so I'll see if my dad can do this for me. What type of welder is best to use?

What do you mean, not to use the tube to go over the pump? Not to be longer than the stocker?

I will be sure to take plenty of pics and try and find a place to host them so everyone on the board will be sure to know how to do this.

Yes, the first part is right. Just make sure before you weld that it is the right lenght so the fuel pump has enough room to fit in right.

For the tube, don't take just the 1/2 tube to try to put it over the outlet nozzle of the pump. That is why I told you to use the stock fitting piece and have the tubing welded into it. Basically so you could use the o-ring and have it just like stock.

If you need something to go off of just use some of the pictures on my gallery for this. But, it would defenatly be great to add more.

 

[Gamble97]

Perfect, thanks for all the help. I'm going to give it a shot tomorrow and through the weekend. Bonus points for you!

 

[Gamble97]

If you pop your back seat off anytime soon can you take another pic, the ones in your profile are very small? Is that brass fitting on in the AN fitting or at the bottom of the AN fitting

 

[hopwoodp]

If you pop your back seat off anytime soon can you take another pic, the ones in your profile are very small? Is that brass fitting on in the AN fitting or at the bottom of the AN fitting

At the bottom of the an fitting. I will try to blow up the picture some. Thanks man.

 

[Gamble97]

So the fitting goes on first, then the AN fitting? Did you try and pull it right off to see if it would move?

 

[Gamble97]

Does this get drilled out to 1/2" or another size? My worry here is that it will not be tight on the fuel pump itself

 

[hopwoodp]

Does this get drilled out to 1/2" or another size? My worry here is that it will not be tight on the fuel pump itself

Drill it so that the tube will fit inside. You may need to trim more if needed. Just make sure to get a good weld on there.

What do you need to know about the fittings? I didn't really get the question.

 

[Gamble97]

With the gold fitting, does that go on in the AN fitting?
Also, some people are telling me that you have to flar the tube so it doesn't leak, by using a 37degree flaring tool.
Any truth to this?

 

[11sec_GSX]

Does this get drilled out to 1/2" or another size? My worry here is that it will not be tight on the fuel pump itself

You really do not need to drill that piece out that much. I put my 1/2" tubing over the smaller end of that piece and then welded it into place. There should be an o-ring on the bottom side of that piece. It will be plenty tight if you follow this procedure....Slide that piece down onto the top of the fuel pump outlet. Then bolt the pump into position on the bracket. Now you know the fuel pump is in the proper location. Then slide the 1/2" tubing down through the hole in the fuel pump assembly and push it over the piece as I explained I did above and then weld it into place. Sorry guys I haven't checked this thread forever...

 

[11sec_GSX]

With the gold fitting, does that go on in the AN fitting?
Also, some people are telling me that you have to flar the tube so it doesn't leak, by using a 37degree flaring tool.
Any truth to this?

The AN to tubing adpater uses a compression fitting and does not need to be flared.

 

[11sec_GSX]

My fuel pump assembly does not screw on like that, it has a series of nuts around the edge holding it on. Will I still need a jam nut to clear them do you think? I am just trying to plan it out before I get in there.
You said that you had one jam nut on topside of the assembly and two on the bottom side. Maybe this will be self-explanitory once I take off the assembly and see how its put together but once you stick the 90* bulkhead through your new hole with a jam nut on the top side, and two at the bottom (why two?), what does it attach to on the other side?

Does the AN to Tube adapter seal the tube connection good enough? Doesn't it just push in there?

And I have an Aeromotive FPR, whats the best way to find out what size fittings are needed since apparently there are different ones?

You should use a jam-nut on the top and bottom of the bulkhead regardless of cleareance issues. I used two jam-nuts on the bottom because it provides stronger lock. And it doesn't connect to anything inside the tank, it's for the return line which just drops fuel back into the tank.

The AN to tubing adapter uses a compression fitting and seals fine.

The Aeromotive inlet and outlet fittings are a -6AN thread or 9/16"-18, they are the same thing.

 

[11sec_GSX]

Nice job on your setup hopwoodp. It looks familiar.