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I’m starting this thread to document converting my returnless fuel system to a return style fuel system with the help from Aeromotive Fuel Systems Inc and Fuel Safe. I’m going after big power and I want a fuel system that can easily support that. Our OEM LPFP, DW300C upgrade and Walbro 525 (mod) aren’t going to cut it. I want something the pros use and it all started with an inquiry to Aeromotive.
Walking me through the process Brett C. from (Aeromotive Fuel Systems Inc) started me off with what type of fuel did I plan to use and what are my power goals. I said I wanted to use E85/100% meth and wanted to see a max output of 800awhp. Based on my turbos of choice he figured about 35 psi boost and derived an air to fuel ratio as a guide for a low pressure fuel pump. I did vocalize that I was willing to ditch the OEM tank and use a fuel cell. Well that opened up a bunch of doors that would otherwise be off the table.
I had my homework of contacting Fuel Safe and Xtreme-DI. Fuel Safe to ask for help choosing a fuel cell (Aeromotive and Fuel Safe frequently partner up) and to ask Xtreme-DI what the DI HPFP needed for pressure. So their DI pumps need at least 70 psi to operate efficiently and said as low as 60 psi will **** it. They also recommended installing an in line fuel pressure gauge stating that there is some pressure drop to the pump and what it says it has and what it actually has may not be the same, adding the more pressure the better. Brett’s plan is to have it at 70 psi constant for idle and low load and boost reference for higher loads and 90 psi constant WOT.
Scott from Fuel Safe has been very helpful and this is what I’ve got coming.
Today I had to quickly call and pay to add their sending unit provision and sending unit ohm range of 10-180 which is our OEM range. Thanks @Ecoboost_xsport for that info!
So this is a 12 gallon version which is 9.5” height (deep) and what Brett said will work with this badass brushless 3.5 GPM LPFP
It’s like the size of my Alky Control Meth pump! Massive! Check out the specs, it’ll easily support 1200hp on E85.
Brett said it’ll need a fuel pressure regulator installed in the engine bay right before the DI pump
He said the fuel will get cooled significantly on the return and back so nothing to worry about as far as hot fuel and city driving, he said you can “drive it anywhere”. I’m going to need a drive by wire tps signal so he recommended I find out if I can use this
Brett sold me all the hard parts along with Aeromotive’s fill plate.
Here’s a complete parts list from Aeromotive
I’m still waiting on the fuel cell but the plan is to get all the hard parts “roughed in” then I can call back and get lines made to exact lengths. And if I run into anything I’ve got Brett and Scott at a phone call away! Brett and I alone had almost 30 emails back and forth! Very good customer service for both companies! Stay tuned to see how this plays out! For reference this new return style fuel system is going to be integrated into the stock ecu for now and paired with Xtreme-DI 2000cc fuel injectors and the XDI60 HPFP.
Walking me through the process Brett C. from (Aeromotive Fuel Systems Inc) started me off with what type of fuel did I plan to use and what are my power goals. I said I wanted to use E85/100% meth and wanted to see a max output of 800awhp. Based on my turbos of choice he figured about 35 psi boost and derived an air to fuel ratio as a guide for a low pressure fuel pump. I did vocalize that I was willing to ditch the OEM tank and use a fuel cell. Well that opened up a bunch of doors that would otherwise be off the table.
I had my homework of contacting Fuel Safe and Xtreme-DI. Fuel Safe to ask for help choosing a fuel cell (Aeromotive and Fuel Safe frequently partner up) and to ask Xtreme-DI what the DI HPFP needed for pressure. So their DI pumps need at least 70 psi to operate efficiently and said as low as 60 psi will **** it. They also recommended installing an in line fuel pressure gauge stating that there is some pressure drop to the pump and what it says it has and what it actually has may not be the same, adding the more pressure the better. Brett’s plan is to have it at 70 psi constant for idle and low load and boost reference for higher loads and 90 psi constant WOT.
Scott from Fuel Safe has been very helpful and this is what I’ve got coming.
Today I had to quickly call and pay to add their sending unit provision and sending unit ohm range of 10-180 which is our OEM range. Thanks @Ecoboost_xsport for that info!
So this is a 12 gallon version which is 9.5” height (deep) and what Brett said will work with this badass brushless 3.5 GPM LPFP
It’s like the size of my Alky Control Meth pump! Massive! Check out the specs, it’ll easily support 1200hp on E85.
Brett said it’ll need a fuel pressure regulator installed in the engine bay right before the DI pump
He said the fuel will get cooled significantly on the return and back so nothing to worry about as far as hot fuel and city driving, he said you can “drive it anywhere”. I’m going to need a drive by wire tps signal so he recommended I find out if I can use this
Brett sold me all the hard parts along with Aeromotive’s fill plate.
Here’s a complete parts list from Aeromotive
I’m still waiting on the fuel cell but the plan is to get all the hard parts “roughed in” then I can call back and get lines made to exact lengths. And if I run into anything I’ve got Brett and Scott at a phone call away! Brett and I alone had almost 30 emails back and forth! Very good customer service for both companies! Stay tuned to see how this plays out! For reference this new return style fuel system is going to be integrated into the stock ecu for now and paired with Xtreme-DI 2000cc fuel injectors and the XDI60 HPFP.
