Thursday, June 23, 2011

It Runs - Fuel System Part 2

Now, determined to get my Mustang started, I ordered a new in tank pump and a new in tank pickup tube.  Other than the crappy Ron Morris 'Sending Unit' , I had not seen anything that would be plug-n-play with my 65 Mustang fuel tank so I need to make something.  Looking at the online auto part sites, I found a perfect pickup tube from part #FG30B for a 93 Mustang for $89.99 and it even has the fuel pump plug and leads.  Its also has a 3/8" tube.  This 'hangar' is actually a 2 piece unit, held together with 4 screws.  I could also cut and weld if needed.   Next I got a Walbro electric fuel pump part# GSS307, a 255 lph in tank pump.  It comes with a pigtail plug and small hose, clamps, and a strainer.
I started my custom setup by unscrewing the bottom half of the hangar and attaching it flipped around in the opposite direction and the small tabs bent out of the way.  I used 2 #8-32 screws and nylock nuts so the bottom section could swing freely.  The outer cover fits only one way so I had to make sure I could get the angle of the whole assembly correct and match the approximate angle of the original sender unit and still be able to let it flex.  

Next, I installed the pump into the bracket. It is held in place by the strainer and a zip tie. I also added a couple of wide rubber bands to the pump for extra noise isolation.  I also cut off the end of the return line above the elbow since it interfered with the pump.  I then cut the pre-bent hose that came with the pump so that it was just a single curve that was long enough to allow the assembly to flex enough installation. This must be EFI rated fuel hose. I also soldered the wires from the pump to the hanger plug and covered with shrink tube.  The pump bracket is clocked a little from vertical but not enough to be a problem since the bracket flexes toward the bottom.   
To install the new pump unit into the tank, it must be folded a little to fit through the hole then once in the tank, allowed to straighten and drop to the bottom.  The cover plate is exactly the same as the 65 unit so it fits right in. 
The only catch is that it uses a funky connector so I had to order a 93 Mustang fuel sender plug from CJ Pony Parts #HW2606.

With the pump installed and plumbed there's nothing left except to start it up.

Thursday, June 16, 2011

Shocking Wiring and Fuel Fouled Up

I'v gotten a lot of engine compartment work completed.  The power wiring is nearly complete and I just need to get the looms in and tidy up a little.   The battery is located in the right side of the trunk and the power is routed to the front using a Moroso 2Ga cable passing over the right side wheel house, along the edge of the floor and through a grommet  in the fire wall then along the frame rail to the former battery location. The cable connects to a lug on the starter solenoid and every thing that needs 12v is connected to that same lug. The engine and starter are grounded to the body via a short 1Ga wire I got from my brother-in-law.

The new fuel system is composed of 3/8 steel tubing, an in-line fuel pump, and a fuel filter.  The fuel pump is Professional Products 220 LPH EFI fuel pump #70151.   I also have a new Ron Morris efi conversion pickup tube and sender for the 65's tank.   
I hand bent the feed and return lines and connected them to the filter and pump, then connected the pump to the tank with efi fuel hose.   The front side connections were through another efi fuel hose to a spring lock fitting to the stock fuel rail.   I then wired the pump to the pink wire from the RJM wiring harness for power and a short wire to body ground.   To prime the system, I jumpered the eec test connector which switches the relay on.  Hmmm, pump is running but no fuel is coming out of the hose at the rail.  After some trouble shooting, it turns out that the Professional Products pump cannot pull the fuel up and out of the tank, even though the pump is a little below the tank.   I think I will need a normal in-tank pump -- even a stock pump will work.  Stock was fine for my old 300+ hp blown set up so it should be fine here. ..To be continued...
A note about the Ron Morris pickup tube.  During installation, the return fuel line tube fell out in my hand.  It seems that the soldering was really bad and probably would have leaked all over if it hadn't fallen out.  Should have returned it but I just tried to sand the pipe for soldering with enough solder to hold it tight and seal it -- but that didn't hold.  Bottom line : DO NOT BUY A RON MORRIS RMP 9112 SENDING UNIT !!! THE TUBES WILL FALL OUT AND IT WILL LEAK FUEL. IF YOU HAVE ONE SEND IT BACK TO CHINA.