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Hot!EFI Fuel System

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PeterM
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2016/08/01 19:29:21 (permalink)
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EFI Fuel System

Hi All,
 
I am converting a Mk2 2 litre Escort to turbo charged with modern EFI however wish to retain the standard under boot floor fuel tank.
 
The car will be a reliable quick street car. No track work.
I do not wish to cut large holes in the body shell.
 
Can anyone suggest best design and layout and placement for fuel pump/s, regulators, return lines etc?
 
Thanks!

 
 
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    ratta tat tat
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    Re: EFI Fuel System 2016/08/01 23:57:41 (permalink)
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    Hi Peter. I've just been through this planning process myself. You'll need to put a lift pump under the boot floor somewhere (there's not much room!) because the pumps are designed to push the fuel. If they pull, they burn out.
    Then you'll have the swirl pot and EFI pump in the boot which I think defeats the purpose of having a drop tank.
     
    A customised factory drop tank with built in swirl pot can be done which would eliminate the need for a lift pump and keep everything out of sight under the floor.
     
    I opted for a GRP4 fuel cell with pumps & pot in the boot because the tank popped up cheap and I found out that it's not really that much of a problem to get a mod plate for boot fuel systems
    post edited by ratta tat tat - 2016/08/02 00:15:11
    #2
    ratta tat tat
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    Re: EFI Fuel System 2016/08/02 00:09:04 (permalink)
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    Here's my boot. Still a lot to do

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    ratta tat tat
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    Re: EFI Fuel System 2016/08/02 00:12:29 (permalink)
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    Some more. I forgot to mention GRP4 now do their tanks in two styles one being injection that has a built in swirl pot
    http://grp4fabrications.c...31&products_id=139
     
    post edited by ratta tat tat - 2016/08/02 00:19:28

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    #4
    RS 2000
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    Re: EFI Fuel System 2016/08/02 14:05:42 (permalink)
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    In SA any fuel pumps, fuel hoses, surgetanks in boot area etc can not be passed unless enclosed in a Vapor proof enclosure that is vented outside,accompanied by relevant engineers report of course.
    #5
    Escortpower
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    Re: EFI Fuel System 2016/08/02 20:09:09 (permalink)
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    PeterM
     
    Can anyone suggest best design and layout and placement for fuel pump/s, regulators, return lines etc?
     
    I do not wish to cut large holes in the body shell.
     
    Thanks!

     


    Here's mine Peter. This is version 2, Commodore fuel pump assembly inside original tank. Works a treat.
     
    Version 1 was original carby fuel pump feeding a swirl pot in the engine bay which then fed a bosch 910 pump mounted to the inner guard. The excess fuel went back to the swirl pot then back to the tank. It used the original plastic fuel lines to & from the tank. Worked well for about 6 years.
     

     
    Cheers, Craig. 

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    #6
    Eskie92
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    Re: EFI Fuel System 2016/08/02 21:25:06 (permalink)
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    My mate has EFI his 2L in his MK1 Panelvan. Looks quite straight forward but will have to ask how his is done.

    http://www.classic-ford.org/cfp/tm.aspx?m=69553
    WTB: MK1 Escort Parts - List Inside
    #7
    what?
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    Re: EFI Fuel System 2016/08/02 21:33:50 (permalink)
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    PeterM
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    Re: EFI Fuel System 2016/08/03 17:38:13 (permalink)
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    Thank you for your replies!
     
    Why is a swirl pot/surge tank necessary for a street car?
     
    Thanks.
    #9
    RS 2000
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    Re: EFI Fuel System 2016/08/04 21:50:35 (permalink)
    +1 (1)
    It's necessary for any efi engine, as soon as fuel surges you get instant fuel pressure drop which causes instant lean out of your mixtures.

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    #10
    BootOn
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    Re: EFI Fuel System 2016/08/05 13:10:59 (permalink)
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    RS 2000 is correct in saying that if you starve the efi pump for fuel then your mixture will lean out and bad things will happen but a surge tank isn't the only answer; I can't think of a single car that runs one from the factory. A sump in the tank where the pump draws from, internal baffles, foam etc etc are all methods which will reduce the chance of starvation? In my mind the surge tank system is overkill for a road car, it's another pump to potentially fail, another circuit to go wrong better to engineer out the need for it.
    #11
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    Re: EFI Fuel System 2016/08/05 17:12:33 (permalink)
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    http://www.turbosport.co.uk/showthread.php?t=163296
     
     
     
    Here is how me and my brother did it on the 2,6 Pinto Mk-1 in tank Valbro pump.

    The fuelpipe goes through the tank and out orginal outlet on tank. (not "conected" to the fuel inside the tank)





    A bracet was made and welded to the cover and the pump was mounted with hose clamps. (sorry,no picture of this...)









    Everything was Tig welded.




















    Orginal RS2000 sender with return pipe was used to the fuel return.
     
    #12
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    Re: EFI Fuel System 2016/08/05 17:24:53 (permalink)
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    http://www.speedhunters.com/2016/03/project-kp61-finicky-bits-begin/FINAL CHAPTERA Surge Of Motivation

    Mounting the engine, the gearbox, and even shortening the diff to suit the car – all of that could be considered the ‘fun’ bits of piecing together a project build. The not so fun bits? Putting the ‘services’ throughout the car. Likened to a building, this is the plumbing, the wiring, the fuel system – and this, possibly the single most boring photo ever posted on Speedhunters of the car’s original fuel tank post-acid dipping exemplifies the initial enthusiasm with which I approached the task of fuel.

    In a nutshell, the original tank, designed to suit a carburettor, wasn’t going to suit the fuel system in its standard state. That is to say, I wanted an in-tank type pump with no mucking around with lift pumps, surge tanks and main pumps all cluttering the underside of the car. So we needed to design and build a means of preventing fuel surge and accommodating an in-tank EFI-type fuel pump. This job was entrusted to Jon and Chris of Strange Workshop in Auckland, who also did some top-notch work on Taryn and Pedey’s Project Z a while back. The first step was to chop open a sacrificial tank, and work out what we were dealing with.

    Once the location for the inbuilt surge compartment was ascertained, why not make it easy by cutting the required section out of the scrap fuel tank, transcribing the measurements onto the ‘good’ tank and marking it out ready for cutting.

    Jon’s a deft hand with a grinder, taking on an ‘easy does it’ mantra. The old adage of measure twice, cut once, was adhered to as the grinder made short work of the factory steel tank.

    The scrap fuel tank also donated the flange which would accept the new fuel pump cradle; incidentally this flange originally served as the filler for the tank. The flange was chopped out, ground and linished to a round shape then welded in place on the tank where the original carb fuel lines would have been located.

    In the meantime, Chris cracked on with the surge tank, folding up a compartment of roughly 3-litres in capacity using some fresh sheet metal.

    Step two was of course to TIG-weld the joins of the surge tank together.

    Then all of a sudden, a simple rectangular container is the net result, ready to be test fitted against the hacked up fuel tank.

    The initial test fit involved ensuring the surge tank was sharing the same vertical plane as the fuel tank would when mounted beneath the car. The seam running around the circumference of the tank offered a simple reference.

    Tacked in, awaiting final welding the companion to the tank mounted flange began to take shape. Again born of a repurposed part, we elected to use a pair of -6AN fittings welded to steel feed and return lines below the tank with a steel cradle slung beneath accommodating the pump itself.

    Without the surge tank installed, the assembly looks something like this – mounted on its side with ample fuel to draw from is a Walbro fuel pump with a flow capability exceeding that of the fuel requirements the 4A-GE might have.

    And out of the tank, the pump itself dummied up within the surge tank giving an indication of how the setup should work. As the walls of the surge tank protrude above the bottom level of the tank, several holes were required to permit the draining of fuel into this compartment, but sparing enough to trap fuel inside when levels get low to reduce possibility of fuel surge under cornering or acceleration. In theory, the fuel warning light will illuminate long before this is even getting near empty which I hope will provide enough of a safeguard to refuel.

    It’s a time-hungry process. So the next time the fab shop hands you an invoice, before disputing the cost definitely take a moment to consider the time and expertise spent solving the problem you’ve presented them. In my case the tank is not completely finished (awaiting final welding, leak testing and refinishing), but Project KP61 is definitely taking some giant leaps forward thanks to some talented fabrication assistance.
    Next on the list is to bend up a variety of brake hard lines from the pedal box to each corner of the car, and then to start tackling the wiring loom and solve a couple of niggly little problems, one of which is finding a suitable heater tap to mount beneath the dash. Either way, I’m motivated, and blessed with some of the best friends a car nut could want to crack on with getting this thing to the finish line!
    Richard Opie richy@speedhunters.com Instagram: snoozinrichy
    #13
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    Re: EFI Fuel System 2016/08/05 17:26:23 (permalink)
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    Something like the above would be a neat option, however unless you can do the work yourself would turn out quite pricey.
     
    #14
    gazz
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    Re: EFI Fuel System 2016/08/06 08:18:15 (permalink)
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    if i was using the drop tank from the mk2 i would be fitting a surge tank/swirl pot. those tanks aren't baffled and so fuel sloshes around like you wouldn't believe! 
    #15
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