New Fuel System (lots of pix - not dialup friendly)

Okay so we are almost done and it seemed like a good time to share this, as all of the components are in place and I think I can reasonable explain why we did what we did. For those who did not know, I have been having some problems with my fuel system, in particular, suppling enough fuel to feed the Whipple 4.0. I tried a couple of easy fixes that didn't work. So I just bit the bullet and did a full fuel system replacement. The new system uses a Kinsler mechanical pump and incorporates returns lines so that a pressure regulator can be used (instead of computer controlled electric pumps). This should be a more reliable system with almost no limit on amount of fuel that can be delivered. Which leaves me with race fuel and E85 as possible tune options.

This is the fuel pump we (me and my tuner Shawn Fischer) decided to use. Kinsler makes a good product and he stands behind what he sells. This pumps also exceeded every performance marker we were looking for.


The pump was to be shaft driven off the back of the oil pump. Kinsler helped us with methods to accomplish this in such a way that he proven reliable on other vehicles they have been involved with.


During the course of fabrication, Shawn was introduced (SEMA) to the people who make this race inspired fuel line connector. See Phenix Industries for more details. We decided to reroute the blow-by valves while we were working on the system.


The first step was to research what we were dealing with. Shawn spoke directly with several of Fords suppliers and we extremely impressed with some of the fuel strategies. In the end we decided to incorporate as much of the OEM pick-up system as possible. He area few pictures of the fuel cell cap and then the inside of the fuel tank (aka: can of worms)

OEM fuel cell cap #1


OEM fuel cell cap #2


Inside of fuel tank


This is where we found our first "AH HA" situation. One of the fuel lines inside the tank was installed at the factory improperly. It was about two inches to short. This caused, what should have been a nice gradual turn to be a crimp. We suspect that when the system was pressurized the line would straighten our but as fuel consumption reached its peek, pressure dropped and then the line re-crimped. That would explain the very wavy fuel ratios we saw on our last dyno runs.


The, soon to be new fuel cap, next to the oem cap.


Time for a new fuel cell cap. Main Fuel pump supply line - Breather Line - Main Return Line - Fuel Jet Return Line - Internal sensors


This was probably the trickiest part. There was just so much technology here that you don't see on most cars.




like a glove :thumbsup


Lines attached


back in the car


Next we had to get the new fuel pump mounted to the back of the oil pump. The plan was to create a new rear plate for the oil pump that would allow us to utilize the oil pump drive shaft and mount the new fuel pump.

Oem oil pump


Oil Pump insides - cool stuff


For anyone who has changed the oil pump belt, you'll recognize this little jewel


And finally the entire lego ship, disassembled. (I love this stuff)


Okay, so we are done playing around and it's time to get down to business. A custom plate must be drawn up in CAD


Then created in billet aluminum.


Placed on the pump


Then on the car


Assortment of lines, primer pumps, filters, magic fairy dust


http://www.fordgtforum.com/forums/attachment.php?attachmentid=17166&d=1285634460[/imh]

[img]http://www.fordgtforum.com/forums/attachment.php?attachmentid=17161&d=1285634448






And finally tomorrow we plan to bring her to life. Cross your fingers, it will either be super badass or it will burn to the ground. :confused

Good times.

Stock fuel rails didn't like being heated. They are made of a VERY thin piece of SS. I suspect Ford wanted the rails to absorb some of the back pressure from the injector pulses. However it makes them more delicate than aftermarket rails. If anybody has a hookup on fabricated rail please let me know, otherwise I am off to the CAD machine again.

911teo said:

Will you sell it as a Kit when you are all done? :biggrin:biggrin

Click to expand...

The first one has your name on it.

The standard size rails are all I need to get her on the dyno. I would love to lighten your inventory a little.

B.M.F. said:

Mark i have 2 sets of rails done. I did 4 sets @ once. I can do them for tall inj or short inj.

Click to expand...

By the way, I've been waiting for you to ask me how I got around the motor mount I didn't, we just CNC a new mount that went around the pump.

It didn't go well.

The pressure test showed that we had some pinhole leaks in the stock fuel rails so I'll have to order so billet rails and try again in a few days. I'll let you know how it goes.