Recommendations for EFI fuel system

[ArdWrknTrk]

I didn’t reuse the old hanger because my truck is a carbed 84 so the hanger does not have a return. I needed a return for the EFI but wanted the level sender to be the same so I used an 85-86 unit.

Here’s a couple of pictures of the final installation:

Amazing pic's Chad!

To get lighting and focus like that inside the tank.

Looks like your pump on a stick setup is going to work out just fine.

[Littlebeefy]

I understand you used a 85/86 unit why did you cut the cradle off the OE 85/86 unit is my question. Ive installed walbro pumps using the OE hanger with no need to modify it.

Use the OE rubber grommet for the 85/86 sender but instead of using the OE lift pump install a walbro high pressure pump in its place. Worse case you might have to trim a little off the hardline that is above the pump for clearance but that is about the worse youd have to do.

Rusty,

I don't know how it's possible to use the 85/86 hanger in a 2" tank hole without cutting off the pump mount portion if you want to use a Walbro 255 or similar sized pump. I simply can't make the math work no matter how I sort it. Are you aware of a version of the Walbro 255 that does not have a 39mm body?

The issue with the stock pump and hanger is that the pump has an outlet and tube at the bottom of the pump, so the fuel pickup tube runs alongside the pump. In order to use a Walbro, you'd have to plumb a fuel hose from the top of the pump down to the pickup inlet at the side of the pump, which means you now have 2 additional parts of your pickup running up and down beside the body of your pump.

So just take the simplest scenario so we don't have to get into trig. The diameter of 2 inches is equal to 50.8mm. Assuming we are dealing with 1 dimension for simplicity, that leaves 11.8 mm between the body of the pump and the edge of the tank opening. The metal pick-up tube with the inlet next to to the pump is 9.5mm wide. So I'm left with 2.3 mm of linear distance to accomodate the hose and hose clamp (which is going to be BOTH between the pickup hose and the pump and on the other side of the pickup). So I need to find a hose and clamp combo that is less than 1.15 mm in wall thickness, which I'm pretty sure doesn't exist. Now remember that I have to account for another hose alongside the pump, clamps to hold the pump to the pickup and the actual plate that the pump mounts to which is 1mm thick. If I can't make it work in my fictitious, idealized thought experiment, how on Earth could you possibly do that in reality.

Forgive my incredulity, but I don't see how it's possible to fit a Walbro 255 to an 85/86 hanger without modifying the hanger, at least in a way similar to what I did, and still be able to get it into a tank with a 2" hole. I looked online and couldn't find anyone who had been able to do that with anything but the later hangers that use the larger hole.

I'm from Kansas so show me.

 

[Rusty_S85]

Rusty,

I don't know how it's possible to use the 85/86 hanger in a 2" tank hole without cutting off the pump mount portion if you want to use a Walbro 255 or similar sized pump. I simply can't make the math work no matter how I sort it. Are you aware of a version of the Walbro 255 that does not have a 39mm body?

The issue with the stock pump and hanger is that the pump has an outlet and tube at the bottom of the pump, so the fuel pickup tube runs alongside the pump. In order to use a Walbro, you'd have to plumb a fuel hose from the top of the pump down to the pickup inlet at the side of the pump, which means you now have 2 additional parts of your pickup running up and down beside the body of your pump.

So just take the simplest scenario so we don't have to get into trig. The diameter of 2 inches is equal to 50.8mm. Assuming we are dealing with 1 dimension for simplicity, that leaves 11.8 mm between the body of the pump and the edge of the tank opening. The metal pick-up tube with the inlet next to to the pump is 9.5mm wide. So I'm left with 2.3 mm of linear distance to accomodate the hose and hose clamp (which is going to be BOTH between the pickup hose and the pump and on the other side of the pickup). So I need to find a hose and clamp combo that is less than 1.15 mm in wall thickness, which I'm pretty sure doesn't exist. Now remember that I have to account for another hose alongside the pump, clamps to hold the pump to the pickup and the actual plate that the pump mounts to which is 1mm thick. If I can't make it work in my fictitious, idealized thought experiment, how on Earth could you possibly do that in reality.

Forgive my incredulity, but I don't see how it's possible to fit a Walbro 255 to an 85/86 hanger without modifying the hanger, at least in a way similar to what I did, and still be able to get it into a tank with a 2" hole. I looked online and couldn't find anyone who had been able to do that with anything but the later hangers that use the larger hole.

I'm from Kansas so show me.

A Walbro 255lph fuel pump is not much bigger than a OE stock in tank electric fuel pump.

Now in my case im looking at the GSS342BX which is a GSS342 series of pump the BX is for a 96 Mustang by application while non BX is just your generic universal. The mustang variant I found can be purchased for less via rock auto than the non BX.

First this is a NOS sending unit that I got the photo off ebay that shows the pump and the pump cradle. This is a low pressure low volume lift pump.

This here is the walbro line up of in tank high pressure fuel pumps. One I will be using is the top GSS342 with the 11mm inlet which will allow the use of the holley fuel mat.

And this is the dimensions of the Walbro GSS342 series of fuel pump which is 255 LPH.

As you can see the pump has a max PSI of 124, is 255 lph fuel flow output is 11mm or 3/8", inlet is 11mm, the diameter of the pump is 40mm and the length is 120 mm.

It will fit in the OE hanger just fine. You may or may not have to cut the fuel pressure feed line above the pump for clearance but on the 85/86 sender I used on a '82 F150 I installed a 5.0 coyote in at work I didnt have to cut the OE sender and a foxbody mustang high volume high pressure Walbro pump fit just fine without modifications to the cradle. You may feel safer with having a clamp to hold the pump to the support rod but I have never used one as the hose and the rubber isolating through the cradle I found was enough to hold the pump stable.

So tell me do you think a 40mm wide Walbro 255 lph fuel pump is too big to fit through the hold in the OE hanger? The pump is just over 1 1/2" wide. Pump length is almost 4 3/4" long. I dont know the OE lift pump dimensions and you wont find one listed online I dont think as OE replacement pumps dont give dimensions just application they fit as they are not universal but vehicle specific.

I honestly have thrown aftermarket universal or foxbody electric fuel pumps in Fords using the OE ford hangers with no problem on numerous EFI conversions I have done where an aftermarket fuel tank isnt avaliable with a universal fuel pump included.

I dont have a photo of the ones Ive done as I never thought of taking one but if you are interested when I do my EFI conversion on my truck after I finish my engine build Ill gladly photograph the conversion and how I do it utilizing the OE hanger using an aftermarket high pressure high volume Walbro pump.

[Littlebeefy]

Rusty,

I don't know how it's possible to use the 85/86 hanger in a 2" tank hole without cutting off the pump mount portion if you want to use a Walbro 255 or similar sized pump. I simply can't make the math work no matter how I sort it. Are you aware of a version of the Walbro 255 that does not have a 39mm body?

The issue with the stock pump and hanger is that the pump has an outlet and tube at the bottom of the pump, so the fuel pickup tube runs alongside the pump. In order to use a Walbro, you'd have to plumb a fuel hose from the top of the pump down to the pickup inlet at the side of the pump, which means you now have 2 additional parts of your pickup running up and down beside the body of your pump.

So just take the simplest scenario so we don't have to get into trig. The diameter of 2 inches is equal to 50.8mm. Assuming we are dealing with 1 dimension for simplicity, that leaves 11.8 mm between the body of the pump and the edge of the tank opening. The metal pick-up tube with the inlet next to to the pump is 9.5mm wide. So I'm left with 2.3 mm of linear distance to accomodate the hose and hose clamp (which is going to be BOTH between the pickup hose and the pump and on the other side of the pickup). So I need to find a hose and clamp combo that is less than 1.15 mm in wall thickness, which I'm pretty sure doesn't exist. Now remember that I have to account for another hose alongside the pump, clamps to hold the pump to the pickup and the actual plate that the pump mounts to which is 1mm thick. If I can't make it work in my fictitious, idealized thought experiment, how on Earth could you possibly do that in reality.

Forgive my incredulity, but I don't see how it's possible to fit a Walbro 255 to an 85/86 hanger without modifying the hanger, at least in a way similar to what I did, and still be able to get it into a tank with a 2" hole. I looked online and couldn't find anyone who had been able to do that with anything but the later hangers that use the larger hole.

I'm from Kansas so show me.

A Walbro 255lph fuel pump is not much bigger than a OE stock in tank electric fuel pump.

Now in my case im looking at the GSS342BX which is a GSS342 series of pump the BX is for a 96 Mustang by application while non BX is just your generic universal. The mustang variant I found can be purchased for less via rock auto than the non BX.

First this is a NOS sending unit that I got the photo off ebay that shows the pump and the pump cradle. This is a low pressure low volume lift pump.

This here is the walbro line up of in tank high pressure fuel pumps. One I will be using is the top GSS342 with the 11mm inlet which will allow the use of the holley fuel mat.

And this is the dimensions of the Walbro GSS342 series of fuel pump which is 255 LPH.

As you can see the pump has a max PSI of 124, is 255 lph fuel flow output is 11mm or 3/8", inlet is 11mm, the diameter of the pump is 40mm and the length is 120 mm.

It will fit in the OE hanger just fine. You may or may not have to cut the fuel pressure feed line above the pump for clearance but on the 85/86 sender I used on a '82 F150 I installed a 5.0 coyote in at work I didnt have to cut the OE sender and a foxbody mustang high volume high pressure Walbro pump fit just fine without modifications to the cradle. You may feel safer with having a clamp to hold the pump to the support rod but I have never used one as the hose and the rubber isolating through the cradle I found was enough to hold the pump stable.

So tell me do you think a 40mm wide Walbro 255 lph fuel pump is too big to fit through the hold in the OE hanger? The pump is just over 1 1/2" wide. Pump length is almost 4 3/4" long. I dont know the OE lift pump dimensions and you wont find one listed online I dont think as OE replacement pumps dont give dimensions just application they fit as they are not universal but vehicle specific.

I honestly have thrown aftermarket universal or foxbody electric fuel pumps in Fords using the OE ford hangers with no problem on numerous EFI conversions I have done where an aftermarket fuel tank isnt avaliable with a universal fuel pump included.

I dont have a photo of the ones Ive done as I never thought of taking one but if you are interested when I do my EFI conversion on my truck after I finish my engine build Ill gladly photograph the conversion and how I do it utilizing the OE hanger using an aftermarket high pressure high volume Walbro pump.

Rusty,

There’s a fundamental difference in the design of the 33 gallon Bronco tank meaning I couldn’t do what you’re proposing. You may be able to do it with a much shallower tank in a truck. I think the difference in the hangers is important. The OEM pump setup is just different.

[Rusty_S85]

Rusty,

There’s a fundamental difference in the design of the 33 gallon Bronco tank meaning I couldn’t do what you’re proposing. You may be able to do it with a much shallower tank in a truck. I think the difference in the hangers is important. The OEM pump setup is just different.

Thought we were talking truck not Bronco, I looked up the sender for the Bronco and that is a weird ass sender. Wonder if you could use a rear tank truck sender instead.

[ArdWrknTrk]

Rusty,

There’s a fundamental difference in the design of the 33 gallon Bronco tank meaning I couldn’t do what you’re proposing. You may be able to do it with a much shallower tank in a truck. I think the difference in the hangers is important. The OEM pump setup is just different.

Thought we were talking truck not Bronco, I looked up the sender for the Bronco and that is a weird ass sender. Wonder if you could use a rear tank truck sender instead.

How's it ever going to reach the bottom?

[Gary Lewis]

How's it ever going to reach the bottom?

The kit that comes with the 38 gallon tank to replace a 33 gallon tank on a Bronco has extenders for the float and pump. Pretty much the way Chad did it but with different materials.

[ArdWrknTrk]

The kit that comes with the 38 gallon tank to replace a 33 gallon tank on a Bronco has extenders for the float and pump. Pretty much the way Chad did it but with different materials.

I think Chad has the regular 33 gallon Bronco tank. (at least that's my interpretation of his reply to Rusty)

[Gary Lewis]

I think Chad has the regular 33 gallon Bronco tank. (at least that's my interpretation of his reply to Rusty)

Yep. I was just saying that even the big boys having you extending things that way when the tank is deeper.

[ArdWrknTrk]

Yep. I was just saying that even the big boys having you extending things that way when the tank is deeper.

. My literal brain.....