I've been digging through this forum for quite a while doing research on fuel systems. Each "how-to" thread was a good start, but rapidly became cluttered and did not seem to offer a complete approach to a better fuel system. I was frustrated with attempts to find fittings or "fixes" to reuse any part of the stock fuel system.
Here goes:
Design goals:
-6 AN FEED
-6 AN RETURN
1:1 Rising Rate Regulator, after the rail
"Bottle neck fix"
Injectors to support GT3076R (with 100% methanol injection)
aftermarket rail with proper fittings
walbro 255 pump
Here's what I came up with:
Design Concept:
A completely -6 AN system with bulkhead fittings installed in the fuel canister assembly cover. Fuel lines will be installed directly from the bulkhead fittings to the fuel filter (on the rail inlet) and the regulator return port (on the rail outlet). Fuel lines will be supported in engine bay and underneath chassis with insulated 5/8" clamps secured with short self-tapping hardware and/or ziptied in place.
Description of hose to be used (not pictured):
All -6 AN lines are AQP Socketless hose. This hose is rated to SAE 100R6, which covers a sufficient operating temperature range, operating pressure range, and weather/petroleum resistance. The AQP lines are also much cheaper than braided stainless and much easier to assemble. A short section of -6 AN line secured via O-Rings, gasoline safe sealant, and 2x hose clamps was used to connect the pump outlet to bulkhead fitting. Outdated text: A short section of 5/16 line will be used to connect the fuel pump outlet to the -6 AN feed line bulkhead fitting. Hose clamps are NOT required and their use is specifically NOT recommended by the manufacturer for the AQP Socketless fittings.
Parts list:
AEI-13109 Aeromotive Fuel Pressure Regulator -1@135.95 ea
AEI-15633 Aeromotive 0-100 Fuel Pressure Gauges -1@29.95 ea
AER-FBM1512 -6AN to AQP barb, straight -4@5.95 ea
AER-FBM1532 -6AN to AQP barb, 90* -2@14.25 ea
AER-FBM2072 -6AN bulkhead fitting -2@4.25 ea
AER-FCN0615 15' AQP socketless hose, black -2@51.88 ea
EAR-178009ERL 9/16 Stat-O-Seal, pair -2@7.39 pack
EAR-985068ERL -6 AN to -8 AN O-RING -1@9.95 ea
RUS-650133 Fuel Filter -1@24.25 ea
SUM-220166 -6 AN O-RING to -6 AN -1@7.88 ea
SUM-220639 -6 AN bulkhead nut -2@1.95 ea
SUM-G1883 5/8" insulated clamp 10 pack -2@8.95 pack
Boomba Fuel Rail -1@155.00 ea
625 CC (655 cc/min at 43.5 psi actual) injectors, 4 pack -1@288.00 pack
Walbro 255 fuel pump -1@125.00 ea
Special Assembly Notes:
1. Utilize one Stat-O-Seal between the regulator and -8/-6 reducer on the end of the rail.
2. Re-use -6 AN plug supplied with Boomba rail for second inlet on regulator
3. Salvage 1x -6 AN o-ring from factory fuel line adapter and place on outlet end of fuel filter prior to installing on rail inlet
4. Remove white plastic factory regulator adapter from top of Walbro pump and connect with 5/16 fuel line (price/part number not specified). Secure pump within canister
5. 1x Stat-O-Seal, 1x -8AN plug from fuel rail, and 1x stock fuel line adapter will remain unused, all other parts/fittings are utilized
Total Cost/Cost Analysis:
1. Cost of all of my fittings/lines: 409.12
Cost of AGP returnline: 365.00
Cost of PTP bottleneck fix: 99.50
Cost of PTP Queasy: 62.49
(these items were selected because they best represent available aftermarket solutions for the same problems resolved in my setup)
Difference: My setup includes a -6 feed AND return line for $117 less, but requires an aftermarket rail.
2. Cost of all parts: 977.12
Cost of DCR Bottleneck fix w/ 255 pump: 350.00
Cost of DCR Returnline: 440.00
(these items were selected because they best represent available aftermarket solutions for the same problems resolved in my setup)
Difference: My pump does not have the hard soldered connections, but my setup does cost 187.12 more. However, my setup includes the injectors, new rail, and -6 feed and return line for the minimal additional cost.
Fuel Injector Calculations/Results:
Deatschwerks
655 cc/min @ 43.5 PSI= 800 cc/min at 65 PSI
40 PSI base pressure, 25 psi of boost to raise to 65 by 1:1 regulator
Theoretical Max HP: 470
Injectors: 4
BSFC: .55 (assumed)
Max Duty Cycle: 85%
(interestingly, 750 cc injectors would support 540 horse by those calculations)
Disclaimer:
I'm not responsible nor can I be held liable for anything you do on your car. Furthermore, I do not intend to market, sell, or profit from the distribution of this "list" and "instructions."
Remarks:
So there y'all go... a fun novel about fuel. I feel that this is the most comprehensive and exhaustive approach to a "big" fuel system. The price tag may seem frightening, but when it's broken down, it is very economical. This system should be able to support the theoretical maximum of your selected injectors and/or the Walbro 255 pump. This system should also be compatible with E-85.
I'll be installing it soon and taking pictures of the entire install process.
Here goes:
Design goals:
-6 AN FEED
-6 AN RETURN
1:1 Rising Rate Regulator, after the rail
"Bottle neck fix"
Injectors to support GT3076R (with 100% methanol injection)
aftermarket rail with proper fittings
walbro 255 pump
Here's what I came up with:
Design Concept:
A completely -6 AN system with bulkhead fittings installed in the fuel canister assembly cover. Fuel lines will be installed directly from the bulkhead fittings to the fuel filter (on the rail inlet) and the regulator return port (on the rail outlet). Fuel lines will be supported in engine bay and underneath chassis with insulated 5/8" clamps secured with short self-tapping hardware and/or ziptied in place.
Description of hose to be used (not pictured):
All -6 AN lines are AQP Socketless hose. This hose is rated to SAE 100R6, which covers a sufficient operating temperature range, operating pressure range, and weather/petroleum resistance. The AQP lines are also much cheaper than braided stainless and much easier to assemble. A short section of -6 AN line secured via O-Rings, gasoline safe sealant, and 2x hose clamps was used to connect the pump outlet to bulkhead fitting. Outdated text: A short section of 5/16 line will be used to connect the fuel pump outlet to the -6 AN feed line bulkhead fitting. Hose clamps are NOT required and their use is specifically NOT recommended by the manufacturer for the AQP Socketless fittings.
Parts list:
AEI-13109 Aeromotive Fuel Pressure Regulator -1@135.95 ea
AEI-15633 Aeromotive 0-100 Fuel Pressure Gauges -1@29.95 ea
AER-FBM1512 -6AN to AQP barb, straight -4@5.95 ea
AER-FBM1532 -6AN to AQP barb, 90* -2@14.25 ea
AER-FBM2072 -6AN bulkhead fitting -2@4.25 ea
AER-FCN0615 15' AQP socketless hose, black -2@51.88 ea
EAR-178009ERL 9/16 Stat-O-Seal, pair -2@7.39 pack
EAR-985068ERL -6 AN to -8 AN O-RING -1@9.95 ea
RUS-650133 Fuel Filter -1@24.25 ea
SUM-220166 -6 AN O-RING to -6 AN -1@7.88 ea
SUM-220639 -6 AN bulkhead nut -2@1.95 ea
SUM-G1883 5/8" insulated clamp 10 pack -2@8.95 pack
Boomba Fuel Rail -1@155.00 ea
625 CC (655 cc/min at 43.5 psi actual) injectors, 4 pack -1@288.00 pack
Walbro 255 fuel pump -1@125.00 ea
Special Assembly Notes:
1. Utilize one Stat-O-Seal between the regulator and -8/-6 reducer on the end of the rail.
2. Re-use -6 AN plug supplied with Boomba rail for second inlet on regulator
3. Salvage 1x -6 AN o-ring from factory fuel line adapter and place on outlet end of fuel filter prior to installing on rail inlet
4. Remove white plastic factory regulator adapter from top of Walbro pump and connect with 5/16 fuel line (price/part number not specified). Secure pump within canister
5. 1x Stat-O-Seal, 1x -8AN plug from fuel rail, and 1x stock fuel line adapter will remain unused, all other parts/fittings are utilized
Total Cost/Cost Analysis:
1. Cost of all of my fittings/lines: 409.12
Cost of AGP returnline: 365.00
Cost of PTP bottleneck fix: 99.50
Cost of PTP Queasy: 62.49
(these items were selected because they best represent available aftermarket solutions for the same problems resolved in my setup)
Difference: My setup includes a -6 feed AND return line for $117 less, but requires an aftermarket rail.
2. Cost of all parts: 977.12
Cost of DCR Bottleneck fix w/ 255 pump: 350.00
Cost of DCR Returnline: 440.00
(these items were selected because they best represent available aftermarket solutions for the same problems resolved in my setup)
Difference: My pump does not have the hard soldered connections, but my setup does cost 187.12 more. However, my setup includes the injectors, new rail, and -6 feed and return line for the minimal additional cost.
Fuel Injector Calculations/Results:
Deatschwerks
655 cc/min @ 43.5 PSI= 800 cc/min at 65 PSI
40 PSI base pressure, 25 psi of boost to raise to 65 by 1:1 regulator
Theoretical Max HP: 470
Injectors: 4
BSFC: .55 (assumed)
Max Duty Cycle: 85%
(interestingly, 750 cc injectors would support 540 horse by those calculations)
Disclaimer:
I'm not responsible nor can I be held liable for anything you do on your car. Furthermore, I do not intend to market, sell, or profit from the distribution of this "list" and "instructions."
Remarks:
So there y'all go... a fun novel about fuel. I feel that this is the most comprehensive and exhaustive approach to a "big" fuel system. The price tag may seem frightening, but when it's broken down, it is very economical. This system should be able to support the theoretical maximum of your selected injectors and/or the Walbro 255 pump. This system should also be compatible with E-85.
I'll be installing it soon and taking pictures of the entire install process.