New FGT fuel system

[Fubar]

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.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17151&d=1285634378

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.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17155&d=1285634387

During the course of fabrication, Shawn was introduced (SEMA) to the people who make this race inspired fuel line connector. See Phenix Industries (http://www.phenixindustries.com) for more details. We decided to reroute the blow-by valves while we were working on the system.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17154&d=1285634384

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
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17156&d=1285634388

OEM fuel cell cap #2
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17159&d=1285634395

Inside of fuel tank
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17157&d=1285634391

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.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17152&d=1285634380

The, soon to be new fuel cap, next to the oem cap.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17164&d=1285634454

Time for a new fuel cell cap. Main Fuel pump supply line - Breather Line - Main Return Line - Fuel Jet Return Line - Internal sensors
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17153&d=1285634382

This was probably the trickiest part. There was just so much technology here that you don't see on most cars.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17150&d=1285634375

http://www.fordgtforum.com/forums/attachment.php?attachmentid=17163&d=1285634452

like a glove :thumbsup
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17173&d=1285634477

Lines attached
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17170&d=1285634470

back in the car
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17172&d=1285634475

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
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17160&d=1285634398

Oil Pump insides - cool stuff
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17175&d=1285634482

For anyone who has changed the oil pump belt, you'll recognize this little jewel
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17165&d=1285634457

And finally the entire lego ship, disassembled. (I love this stuff)
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17178&d=1285634489

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
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17181&d=1285637332

Then created in billet aluminum.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17174&d=1285634479

Placed on the pump
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17171&d=1285634472

Then on the car
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17169&d=1285634467

Assortment of lines, primer pumps, filters, magic fairy dust
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17162&d=1285634450

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

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

http://www.fordgtforum.com/forums/attachment.php?attachmentid=17158&d=1285634393

http://www.fordgtforum.com/forums/attachment.php?attachmentid=17180&d=1285634601


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.

Good times.

[TSims]

Nice work you guys. So now that you have as much in the fuel system as you do in the 4.0L whipple what are your power goals?!? :)

[Fubar]

Good question, we can approach the final tuning a little more aggressively now that we have enough fuel to do whatever we want. We also moved the BAP over to the ignition system so the top end should smooth out considerably. I am hoping for about 825-850 on pump gas, 925-950 on race fuel and then E85... who knows?

If you are going to be around the shop tomorrow, I'll bring those rails back to you.

[flyinmedic]

Looks awesome Mark. Can't wait to see the results.

[golfinz]

Looks awesome! Cant wait till she is back together

[TSims]

Sounds like fun! I love projects like this. I'll be in between the old shop and the new trying to get stuff done. Just give me a holler!

[Qship5]

Great write-up Mark! It looks like this project was done with "do it right or not at all" approach.:thumbsup2:

[Fubar]

Yes the only factor left that we did not replace was the actual fuel rail. It was our hope that they would accept a fitting on the end for the return system but that hope came to an end last night as we discovered a slight warping in the rail as a result of the heat from welding. While it was very disappointing, it does give me a reason to complete this system properly with custom billet fuel rails. The GT will rest in it's place for at least another week.

[fenderltd]

Pretty wicked Mark, hope it comes to life today!

[TSims]

You need some of these we made...

[Fubar]

You need some of these we made...

Yes, do you have any ready to roll?

[Fubar]

It didn't go well.

http://farm2.static.flickr.com/1228/897648081_e41606728d.jpg

[TSims]

LOL!!! Not funny :)

[Fubar]

LOL!!! Not funny :)

I couldn't use those rails after all. It would have required changing several fittings and because you have to make such a sharp turn at the front of the rails we couldn't just downsize to the line size we choose.

So now we are estimating 3 days in CAD, and 2 days at CNC, then plating. Then I'll get all excited again. *wonder what's next*

[TSims]

You are using -8 feed probably? Why not just use this fitting? It's a VERY tight radius and I probably have some in stock. It would allow you to downsize from -10AN on the rail and transition directly into a -8 SS braided hose.

[Fubar]

You are using -8 feed probably? Why not just use this fitting? It's a VERY tight radius and I probably have some in stock. It would allow you to downsize from -10AN on the rail and transition directly into a -8 SS braided hose.

It's a slightly different geography back there when that supercharger is in that way. The passengers side fuel rail ends just short of the bypass valve actuator. So we could not do any fittings on that end. It became more of a headache the more I thought about it. CNC billet rails are being worked up in CAD now.

[Mr.Big]

Very nice guys!

[Fubar]

I am still waiting on custom fuel rails to be machined up but here are a few pictures of the blow by solution we came up with.

The canister, mounted behind the airbox.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17375&d=1286682978

We used some really nice fuel line connections because this would be so visible under the bonnet glass.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17378&d=1286682984

A better view of the line placement.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17379&d=1286682988

[Fubar]

And the fuel rails, as of 4pm yesterday, being machined out painfully slow.

http://www.fordgtforum.com/forums/attachment.php?attachmentid=17402&stc=1&d=1286932161

[GTCole]

Been watching this thread. You are seriously drinking the Ford flavored Kool Aid. Glad you are undertaking a budget procedure.

[Fubar]

One day closer... I think.

http://www.dfwautoclub.com/forums/attachment.php?attachmentid=2184&stc=1&d=1287022044

[Fubar]

Ever so slowly... The last rail is being machined as we speak. If they complete it tonight, I will dyno tomorrow. I suspect it will be a monday dyno for me tho. Cool stuff to look at anyway.

[RaceMX-M3]

Cool shiz Mark. Hope this all comes together soon. :thumbsup2:

[Qship5]

Impressive to say the least! The GT is not only going to be faster than ever, but it's going to look amazing too! Those fuel rails are works of art machined like that.:thumbsup2:

[Mr.Big]

Those fuel rails are works of art machined like that.:thumbsup2:
:thumbsup2::thumbsup2::thumbsup2:

Lookin' good!!!

[Fubar]

It"s Alive!
http://www.kgcreative.com/wp-content/uploads/2009/09/Its-Alive.jpg

[Qikhawk]

You may call me Igor :D

[GTCole]

Mark, WTF? Are you going to the MILE? A little birdie told me that......

[Fubar]

Finally have everything bolted on.

Cool pressure gauge on the new fuel rail. Probably not necessary but I just thought it would look like something C. Shelby would do (the man was obsessed with fuel pressure).
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17548&d=1287461809


This picture shows why custom rails were necessary on a SC application. Also gives the first glimpse of the braided stainless steel, kevlar lines incased in a heat/fire retardant sheath. (I don't like to be on fire)
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17547&d=1287461807

Good "lay of the land" shot. Thanks for the help with the finishing touches Dave
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17549&d=1287461810


A nice view of the new rail, pressure gauge, trick ass connectors and halon nozzle (Again, I do not like to be on fire... it is a furry person's natural enemy)
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17550&d=1287461812


And lastly, a shot thru the back glass. As you can see it really is not that dramatic of a change in the engine bay. The blow-by ports will get most of the attention from the untrained eye.
http://www.fordgtforum.com/forums/attachment.php?attachmentid=17551&d=1287461815

The old girl fired right up once the system was primed. No drama except that the ECU wanted to know where her fuel pumps went. We will dyno tune tomorrow and pack for The Mile on Wednesday. See you there Chuck?

[Mr.Big]

now lets get that beast tuned and back in action!!!:thumbsup2:

[TSims]

Awesome! Looks and function, can't get any better than that!

[GTCole]

Nope. I'm not going. No car to run. Now I've woke up and realized why you were doing all this. My question is why? Have you done more HP stuff that I've missed? There are gonna be some 1200 to 1800 HP Fords. I'm afraid the cop car won't get noticed on the runs. It's a sad day when a 750 HP Ford GT has too low HP for a MILE event.

Plus, it's deer season. I've got priorities now.

[Qship5]

All I can say is...:adore::adore::adore:

That is as to paraphrase Taylor, beauty and the beast. Awesome stuff Mark!:thumbsup2:

[Fubar]

Okay so you guys know about the problems we had on the car. It was almost completely untested when we took it on a 6 hour drive to Goliad. We obviously found a weak point.

Heat from the headers can penetrate the fuel pump and/or filters and cause the fuel inside them to boil. Once the fuel becomes vapor the pump can no longer function.

The solution is three fold.

1) To move the electric primer pump to a location in the system that forces new (cold) fuel into the mechanical pump AND the pre-pump filter. Basically, just a pumping issues here.

2) To separate the pump and filter from any direct connection to metal that might conduct heat from the motor. ie: non-conductive spacers

3) To wrap the entire exhaust system in an Ikonel housing. Then port air in from the existing side scopes to the front of the new exhaust housing and force the hot air down a designated channel, to an exit in the rear of the car.

Number 3 is the biggie but they should all help under different conditions. 1 & 2 address startup issues and 3 addresses hard acceleration issues (which were relatively minor on the drive to Goliad. The car only scrummed the heat once after a 20-30 minute romp around Austin's new Tollway. (40 - 170 pulls) and a little follow the leader stuff :driver:

Heat shielding should look similar to this:
http://fischermotorsports.com/gallery/Thermal_Barrier/Big/DSCF0518.JPG

[RAC3ME]

Wow. That heat shielding looks really nice! What does something like that run?

[Fubar]

Wow. That heat shielding looks really nice! What does something like that run?

:bawling:

Honestly, I have no idea yet. It has to be done so it wouldn't do any good to bitch about it. I suspect it will be about $2000

[RAC3ME]

Well it looks super clean and like you said it is a necessity. Cant wait to see this beast all buttoned up!

[BlackSheep]

Okay so you guys know about the problems we had on the car. It was almost completely untested when we took it on a 6 hour drive to Goliad. We obviously found a weak point.

Heat from the headers can penetrate the fuel pump and/or filters and cause the fuel inside them to boil. Once the fuel becomes vapor the pump can no longer function.

The solution is three fold.

1) To move the electric primer pump to a location in the system that forces new (cold) fuel into the mechanical pump AND the pre-pump filter. Basically, just a pumping issues here.

2) To separate the pump and filter from any direct connection to metal that might conduct heat from the motor. ie: non-conductive spacers

3) To wrap the entire exhaust system in an Ikonel housing. Then port air in from the existing side scopes to the front of the new exhaust housing and force the hot air down a designated channel, to an exit in the rear of the car.

Number 3 is the biggie but they should all help under different conditions. 1 & 2 address startup issues and 3 addresses hard acceleration issues (which were relatively minor on the drive to Goliad. The car only scrummed the heat once after a 20-30 minute romp around Austin's new Tollway. (40 - 170 pulls) and a little follow the leader stuff :driver:

Heat shielding should look similar to this:
http://fischermotorsports.com/gallery/Thermal_Barrier/Big/DSCF0518.JPG


I saw the picture of that big turbo and got worried for a sec... Whew...:D

[TSims]

That inconel heat sheilding is really amazing stuff. It's crazy money but money well spent. You could easily spend $2K doing the exhaust in it for sure...

[Fubar]

I saw the picture of that big turbo and got worried for a sec... Whew...:D

A little race gas and you still got plenty to be worried about. :whistle:

[OKcruising]

That'll look freakin' sweet! Can't wait to see the finished results.

[Mr.Big]

A little race gas and you still got plenty to be worried about. :whistle:

PUMP gas only!!!
































E85 of course:whistle::D