RySmDPT14

factory 11-14 2500HD flex fuel bucket in which I plan on installing a walbro/ ti automotive 525 hellcat pump


first unclip 4 of these from the outer bucket and it will release the factory pump and filter assembly


And you will get this, larger metal canister is the fuel filter and the fuel pump sits inside, nothing holds it in there but the fuel hose on top, which has to be cut and removed. the white disc on the bottom is the venturi.

the venturi sits on the left side of the fuel bucket and over these one way valves. As fuel is pumped some of the fuel is routed through this venturi which causes a vacuum and pulls fuel through these valves into the bucket, this prevents the fuel bucket from going dry

fuel pump removed from inside of the filter


the venturi, you can see the cone nozzle on right, as fuel is pumped into the bottom nipple it is forced through the nozzle creating a vacuum around the nozzle.


this is where the new feed -8an fitting will be installed, the factory feed will become the return using PTFE line to route excess fuel back into the bucket


top view of where new feed line will attach




-8 an fitting installed, and picture of where I drilled holes through the hex nut in order to attach safety wire so they wont loosen (seen in pictures ahead)


This is the bulkhead fitting I found from MONKEY FAB GARAGE, it holds to 10 GA wires and seals them nice and tight to prevent fuel leaking. This shows the best area to drill in the top hat of the pump. is drilled correctly you can uses the molded busses to prevent the nuts from backing off as well.


Bottom view of the bulkhead fitting installed. on the left you can see the evap fitting, this has to be trimmed to allow the bulkhead fitting to fit flush on the hat.


Here is what I mocked up to fit the new pump, the top disc will clip into the factory housing, and the bottom cylinder holds the fuel pump securely with holes drilled to allow fuel to flow in and around the pump keeping in cool. Made from stainless steel 16 GA


view of how it uses the factory clips


I took apart the walbro harness they supply you, I soldered new 10 GA PTFE wire. Those numbers are what I initially used to make the pump housing and retaining plate. The housing ended up being 70 MM tall and inner hole of the retaining plate 50 MM.


Here is the PTFE hose and oetinker clamps uses to keep the hoses from coming apart. To the right of the tubing you can see the head of a bolt, this travels all the way down to the top of the venturi and holds it down. The factory pump has has the venturi installed directly to the pump housing and its weight/ fitment keep it in place. I ordered a SS T fitting 3/8x3/8x1/4 on ebay for 8$ that allows me to connect the stock corrugated hose to the fitting and other end to the nipple where the venturi attaches to factory pump. This fit perfectly and saves some money.

the final install done. I recommend doing this when its summer or in a shop that is well heated. I had to warm the parts inside the house in order to get them to fit easier. Set up tested great, the venturi still filled the bucket and no leaks. Its not a direct drop in pump and as you can see I had to fabricate a housing to hold the fuel pump in order to maintain the use of the venturi. If you want other pics while i have this on the bench let me know.

Choda

iTrader: (1)

awesome thread and thanks for the detailed write up.

how much are you charging to do this for our fellow PT.net members?

RySmDPT14

boostnut

iTrader: (7)

Would you have any interest in fitting one of these into a 2000 fuel bucket? I can pull the bucket assembly and send it your way if interested.

RySmDPT14

Have any pics of the bucket?

boostnut

iTrader: (7)

Unfortunately I don't, its still in use. There are a number of threads here with pictures, some in the gmt800 section.

RySmDPT14

chevykev

RySmDPT14

chevykev