setting up a fuel system

[Cam-Rush]

ok heres the deal, im setting up a fuel system on my project, its a KE35 and im putting a bigport 16V 4AG in it, the system wont need to be huge, but enough to support sustained high revs, and harsh cornering.

i was thinking i would use a VL turbo fuel pump, feeding a surge tank, mounted in the boot, but my old car had a bad fuel smell on anything that i put in the boot, and on long trips, my girlfriends parents used to wonder why she smelled like petrol when i dropped her off...i dont want that problem again, is it an inherent problem with boot mounted surge tanks? or just a dodgey one in that car?

if anyone has experience with setting up a fuel system please give me any advice you have! and a rundown on what you have and how it performs.
thanks.

[CrUZida]

Have a read of the FAQ, you'll find this thread
http://toymods.net/forums/showthread.php?t=467

As for the smell, I'd say thats more to do with the quality of the hoses you've used.
Some hoses tend to 'breathe' and the fumes escape the rubber.
Many many cars use inboot fuel tanks (JZZ30/UZZ30 Soarers for one) and they don't have any fuel smelling problems.

[45aken]

a good intank setup will cost about the same amount of money as having to buy 2 pumps/surgetank/fittings/lines and it wont smell.

i am in the process of doing the fuel system now, and im running 3/8th lines, 5/16 return, sard reg, and walbro GSS-341 intank 255l/hr pump. getting the tank baffled next(i know someone who owns a fab shop ) so far it's cost me ~$350 with everything brand new, and i know my fuel system will support whatever i do to the 4age (turbo etc etc).

my theory with fuel systems is to do it right the first time, so now matter what u do to the motor you'll never have to worry about it again.

but if you must do the surge setup, use a high quality tube (aka not the black stuff from supercheap). i have this line that i got from the local 'speed' shop which kinda like a normal efi hose, but the outer layer is blue. (dunno brand, but it's good stuff)

[Starfire]

Use good quality components and mount the filter, surge tank and pump(s) in a sealed box in the boot. Should be sweet.

For what you are planning though there isn't a huge load placed on the system. A VL pump can be mounted under the car (next to the tank) feeding from a low mounted hose (kind of a gravity feed) running straight to the fuel rail. The return line can go back to the tank. As long as you feed from a low point it is unlikely that you will have surge issues.

[WDE_BDY]

You already have a vertical tank, so weld a small sump to the bottom of the tank and you won't need to worry about a surge tank or extra pump.

Callum

[Cam-Rush]

thanks guys, having a swirl pot type setup is sounding simpler than i thought...
do engineering shops do stuff like welding a small sump to my fuel tank?

[LeeRoy]

A metal fabrication shop/person would be able to weld/modify that for you. I think the main problem is that i'm pretty sure tanks have a coating inside them to stop petrol eating the tank or something like that so if you modify it you will probably need to get it re coated with the stuff again. your other option would be to get a full alloy custom tank built. Of course the cost would be greater but youd get what you want.

LeeRoy

[WDE_BDY]

Personally, I would get a spare tank from the wreckers to trial it first.
Mark a square area on the bottom of the tank where the sump is to be welded on. Inside this area drill multiple holes up into the tank so as to provide an effective baffle to fuel sloshing out of it and away from the pickup. Then weld the sump (with appropriate fittings) on over top and you are done. Obviously take precautions to ensure all fumes are out of the tank (filled with water or exhaust gasses run through the tank) before you weld and check there is enough clearance for the tank to fit back in the car. Have seen one done where they located a similar setup but triangle shaped at one end of the tank as there was more room.

Callum