Return Fuel System
 

Well...started a return type fuel system today...had the whole intake apart anyway...so here goes


I bought a set of the New OBX Fuel rails.........took a bit of work...fittings wouldn't fit without rework..but after a about a 1/2 hour with a tap...and they went together properly. I hope that when I pressure them up they don't leak.

At this point they are not plug and play...so beware. I think the KG parts ones are worth the extra money

Heres a picture of the primary and secondary rails off the car ...gotta clean them out and install in the morning

I'll post more pictures as it progresses

Is there anything you can't make? I mean, come on man, your making us all look like n00bs :D:

Let me know if you need any help with this setup. I converted my personal RX-8 to a return system and later to a full E85 system using new feed lines and an external FPR etc so feel free to ask.

Good luck with your setup :)

Chirs

Good job on using the aluminum crush warrrshers, Dan. Was going to mention that but it looks like I don't need to. :)

B

Dan's been a busy guy!
Good luck with the project, curious to see how it turns out.

Actually they are the hybrid...O-ring/crush washers. The sealing surface on these rails are not great...they could have been machined better ( groove for a captive o-ring or a wider sealing flange....OH well...what can you expect from E-bay I guess...:(

could anyone tell me what the advantages and disadvantages of this are?

Basically more flow..and hopefully more consistent fuel pressure

This is turning into a lot more work than I thought...there is not a lot of room for stuff under there :)

Found out sometimes the OEM parts are a lot more involved than I would have though...for instance..the injector connectors are different than most aftermarket ones..they are smaller and thinner...the off the shelf ones are bulkier and don't fit easily :) I should have some pictures a bit later of it in the car....had fun getting the injectors in..and all the parts hooked up..

#$@%$@%$#$%^@&@**@

Damn it ......

:) Had to do it..this is a PIA :)

Lol--i know the language you are feeling Dan---!
while you are doing this put a phenolic gasket on your intake?
you are going to warm the fuel up some--dont forget that.
are you returning to the fuel cup? Turbulence with that?
using the stock 5/16 line right?
what kind of fuel pressure probs are you having? Track only?
the 09 pump is working well for us so far. Have you seen one? It address's a lot of issues.
olddragger

Nope...-6AN SS all the way..FPR in the engine compartment 1 micron canister filter...OBX fuel rails

300 LPH fuel pump...secondary pump stayed the same...

Used the stock line for the return line from the FPR.....

Not bad. keep us updated, for i am also doing a e85 switch too.

Well..I got it all hooked up...not without a lot of swearing..taking it apart multiple times to hook everything up so that the puzzle worked in the end :)

There is always one bolt or nut or connector that doesn't behave :(

I hope I don't have a leak..or it will be apart again to tighten it up

I'll post pictures in the morning if it doesn't snow

very nice.

I'm no fuel system expert so i've got a question:
If my memory is accurate, the stock returnless system has a pulse damper on the fuel rail. Is there any value to having a damper on a return type system? Do you have one? I don't think i recognized it in the pic.

You should just tighten EVERYTHING down so then you dont have to take it apart again. lol
Been doing that to my little project and i hope it works. lol

That's one of those....... some say you gotta have..others say you don't kinda things

I have a big canister filter...and the FPR will act as a damper as well..so I don't plan on using one

Hell they make great fire starters too :)

Speaking of which, are you adding a fire suppression system into the track sled?

This is interesting and a full description would be welcome.

I wanted to put in a fuel pressure gauge in when I installed my non-return upgrade. Unfortunately, what I thought would be easy turned into a much more difficult process and I abandonded it. Is there a straight forward way to put in a sender into the fuel line?

You can buy an adapter that fits between the stock metal fuel line and the nylon line in the engine bay....that way it's plug and play without cutting anything. Otherwise if you don't mind going to rubber high pressure line..you can replace the feed line from the fuel rail to the metal line and put a fuel sensor adapter in there....

I think PTP made the adapter?? There was a thread on here somewhere on it a long time ago.

Otherwise look for Russell or Aeroquip -AN fittings..

Well....here it is....Pictures aren't the best..but it's snowing outside :(

Thought that I'd add a list of parts for anyone interested

OBX Fuel rails
4 16mm X -6 AN adapters
4 crush washers
12 feet -6 SS hose
2 X 180 degree -6 to tube
Canton Racing canister fuel filter (1 micron filter) with -6 adapters
Fuel pressure adapter -6 female to -6 male
2 X 90 deg -6 to tube
1 X 45 deg -6 to tube
3 X straight-6 to tube
connectors for FPR..depends on what type you use

I used high pressure rubber tube for the FPR to stock fuel line..and re-used the stock quick connect on both ends...worked well

You also need to modify your fuel pump with a -6AN 90 degree bulkhead fitting and connect the pump the feed line to it

I have to pressurize it next...wish me luck :)

^^

Nice work Dan!!

F'n snow, eh? :P

Looks good, if I had a turbo this is the route I'd want to go. What FPR are you using?

Cant believe the snow. We canceled an autoX today, had about 4 inches at Bremerton motorsports park.

wow....

Snow's good, keeps the intake temps down :)

Back on topic however - I've done this on the buggy with an 044 pump and an 'aeromotive' style billet regulator so I can adjust the fuel pressure - the fuel rail is much cooler when running now, used to have problems with the fuel in the rail boiling when lugging up steep hills at low speed.

Not as pretty as that though, I just modified the existing rail to take some -8 braided hose.

Did you get as frustrated as i did when doing them -6 lines?? Man every time i cut they would un-braid so bad. I ended up rigging something up for them small lines.