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Converting factory return system to e85/e54 for new build

Discussion in 'The Distillery' started by NA97GT, Jul 30, 2019.

  1. NA97GT

    NA97GT Member Established Member

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    Looking help planning out an ethanol compatible fuel system for my new build.
    It seems like most of the complete kits are either for converting from return-less style systems, or are a full blown $2000 cobra tank kit which seems overkill for this car.

    I've considered whether I could run the stock tank with glenn's pickup tube to a pair of external pumps with new teflon lines and filters. I'm unsure of what size lines and pumps I could use to accomplish this. As well as whether aftermarket fuel rails are a necessity.

    Car has existing 1997 Mustang GT return style fuel system and 78lb DW injectors.
    Motor is a MMR900 2V- 9.7:1
    Vortech Si-Trim @15+psi, paxton intercooler
    Stage 2 blower cams

    Any experienced feedback is appreciated.
     
  2. GodStang

    GodStang Well-Known Member Established Member

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    but a used 03-04 Cobra tank, Buy Fore fuel hat and pumps, Run feed line, run return. I recommend upgrading fuel rails but your stock ones should be enough.
     
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  3. gt347mustang

    gt347mustang Well-Known Member Established Member

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    Cobra tank is the right way to do it. External pumps kinda suck to deal with, same with those pickups.

    Dont reinvent the wheel. Go with a proven setup.
     
  4. wirelessguy2005

    wirelessguy2005 4S FED Established Member

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    I am running a complete factory fuel setup on my 97 Cobra with the exception of a canton high flow fuel filter and a walbro 465lph pump. Running 80 lb Ford racing injectors and the motor makes about 500 hp at the crank on e85 and 11 lbs of boost.
     
  5. blownstang4.6

    blownstang4.6 Active Member Established Member

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    500 at the wheels you mean? 500 at the crank would only be about 425rwhp and very low for 11psi and E85. I'm at 508rwhp through an auto on my Mach on 11psi and E85 with only 13.75* of timing.
     
  6. wirelessguy2005

    wirelessguy2005 4S FED Established Member

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    It's a conservative number, made 430 rwhp with the timing turned back. Currently with the timing set at 21 I haven't had the chance to dyno it again but I am fairly certain it's closer to the high 400 range at the wheels

     
  7. NA97GT

    NA97GT Member Established Member

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    Do you know if you are close to running out of fuel at the current level? Not many guys seem to keep running the factory return systems lines over 450whp, so I'm not sure where the actual limit is before upgraded lines/ tank are a requirement.
     
  8. wirelessguy2005

    wirelessguy2005 4S FED Established Member

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    I just bumped up the boost a little as well as the timing, hope to get back to the dyno again in the next 30-45 days and hopefully see 500 rwhp. Fuel system has been rock solid so far. Running the walbro 465 pump and a canton high flow fuel filter, all with the factory lines and fuel rails. I haven't seen any signs of running out of fuel.
     
  9. NA97GT

    NA97GT Member Established Member

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    Do you have p/n's for the pump and filter your using? This may be a viable option I can use to get my car running on E54 and tuned for now.
     
  10. wirelessguy2005

    wirelessguy2005 4S FED Established Member

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    I don't have part numbers in front of me but I bought both parts from Summit Racing, the pump actually came up as a 450lph even though walbro calls it a 465. You will also need to buy an install kit separately for the pump and summit has that as well. If you search by your application you will find all the parts at summit. Just be aware that the pump is to large to fit in the fuel pump hanger with out modifying the hanger. It's really an easy modification if you have a cutoff or dremel tool. You will then need to find a way to secure the pump to the hanger, some guys use a stainless hose clamp however I used one of the stainless adjustable bands that you typically use for securing a cv boot to an axle, they are available at any parts store.


     
    Last edited: Aug 23, 2019

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