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Discussion Starter #1 (Edited)
Over the years dealing with Evo's I found there is no good solution for a surge tank kit that is friendly for a DD,Street, or weekend warrior. So after extensive research of surge tanks and applications I might have found a nice solution to all of our problems.

I will be the test pilot for this little operation, but I think it will works.

Here is what I will be installing. It will run in series with my intake walbro 255hp to feed the surge tank at 0 psi this will allow the pump to to have the most flow but not a high pressure.




As you see I will be using a Bosch 044 style pump from Jay Racing which is a improved 044 pump (higher flow). I will also use a one way valve on out put port towards the fuel rail so I do not have a long prime time and that fuel dosent flow back into the fuel tank.

Fuel Pump



One way valve



Right now the fuel system will use 93 octane. However, it will be compatible with E85 using AN fittings/Lines.

The beauty of this kit is that it has a build in fuel pickup inside the surge tank. So it will always fuel the system. With 1 liter to spare it will be enough for most medium hp applications.

I will keep the thread more updated once I have get the parts and start working on the project.

Here is a diagram of what it looks like.


Cost:

Jay Racing 044 - $189.99
034 Motorsports Surge Tank - $215 + 15 for brackets
Jay Racing 1 way Valve - $49.99 (starts immediately with this installed.)
Various Fittings & Hose - ~$200
Electrical - ~$30

Post Install Notes
So this setup does work. It works great actually thus far. However, a AFPR is required to run this setup. You can't use the stock regulator. Secondly, I am almost positive that this setup requires enlarging the return orifice, refer to my other thread for that issue.

Addendum 1: Line sizes

I figured I would post this info up in case some else is doing a custom build for their fuel system.

These are for the OEM fuel fittings located on top of the fuel pump hanger assembly.

Feed line -Actual Dig Caliper (.377) SAE .375" - AN-6
Return line -Actual Dig Caliper (.255) SAE .250" - AN-4

Addendum 2: Wiring

Hook up a Bosch Relay to Switch a Auxillary Fuel Pump

Basic Diagram



Proper Pin Out - So the OEM Fuel Pump switches on the Auxillary Fuel Pump

30 Battery 12v(+)
85 Fuel Pump Connector (D-22) Terminal No. 5 (12V Switched)
86 Fuel Pump Connector (D-22) Terminal No. 4 (GND) or chassis/battery GND
87 12v(+) to Auxillary Fuel Pump

Code:
View of D-22 Fuel Pump Connector - Located ontop of the Fuel Pump Houseing
 
\ 1 2 3  /
 \ 4  5 /


Splice into the blue wire. It will be the 12v switched to turn on the relay.



Give you an idea of how was going to run the wiring.




Addendum 2: Install Pictures












If you notice I have some extra fittings here. I ran short on the feed line and had to extend the line. I was about 1-2 feet short.



Addendum 3: Parts List: (All Parts I used can be ordered from Summit Racing)

Bosch 044 or Variant Jay Racing 044
034 Motorsport Surge Tank
034 Motorsport Mounting Brackets
15' AN 6 Hose
15' AN 4 Hose
10' 10 AWG Red/Black Wire
5' 12 AWG (Any Color) Wire
8x 10-12 AWG Yellow Crimp Connectors (Loop Style / Plug style)
1x Bosch Style Relay - Able to handle 30A continuous (Magnafuel Carries this relay)
30 AMP Fuse
30 AMP Fuse Holder 8 or 10 AWG
13mm Crush Washers or 1/2" Crush Washers that I dremeled out a bit to enlarge.

AN Fitting & Hose List

Special Fittings

1x Russell Performance 640850 - Russell Fuel Rail Fitting Adapters
Fuel Rail Fitting, Aluminum, Blue, Straight, 3/8 in., -6 AN
1x Russell Performance 640940 - Russell Fuel Rail Fitting Adapters
Fuel Rail Fitting, Aluminum, Zinc, Straight, 3/8 in., -6 AN

Regular

2x AN-6 Straight Fitting
1x AN-6 45* Fitting
1x AN-6 90* Fitting
2x AN-4 90* Fittings
1x AN-6 to M12x1.5mm Fitting
2x AN-4 to M12x1.5mm Fittings

Hose (maybe 1 foot left over from each)

15 feet AN-6 (.375")
15 feet AN-4 (.250")

Addendum 4: Tips

1.) All the M12 ends need to have a crush washer & Teflon tape.

2.) All electrical connection must use teflon tape on the screws in the surge tank.

3.) Install the top of surge tank first. Bottom last.

4.)Order goes: Fuel Pump > Crush Washer > Brass Fitting (comes with pump) > Crush Washer > Top of Surge Tank.

5.)Lube the Viton O-ring. Insert the top with pump into surge tank body. Press to seat flush. Then install the bottom. It screws onto the fuel pump itself. Lube O-rings. Then screw on bottom in place.

6.) Hold top in place w/ 24mm Socket. DO NOT TURN THE TOP!!! YOU WILL BREAK THE WIRES!!! Then screws on the top til tight with 24mm socket / wrench.
 

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I wonder if wrapping it with foam and mounting it on rubber isolators can get rid of some of the external pump noise transmitted. subscribed incase this becomes a good solution.
 

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Discussion Starter #7
I wonder if wrapping it with foam and mounting it on rubber isolators can get rid of some of the external pump noise transmitted. subscribed incase this becomes a good solution.
I think that it would work no doubt. But I think the noise will be less since it is contained in a fluid (gasoline). So I do not think that 044 will be as loud. But adding foam I am sure would help with the noise.

My one concern is...

How will the return be affected by this...

Meaning... since the fuel return is responsible for the venturi effect from the other side of the tank and you will have to Y the return line one going to surge tank and other going to the fuel tank itself. Will we lose the venturi effect from decreased fuel pressure. However, I think with a adjustable FPR you will still be able to main adequate pressure to retain the venturi effect.
 

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Discussion Starter #11
Yes, it will be very clean. I am just waiting for parts to arrive so I can go to Summit and get the fittings there locally and see what will work. I think we can fit it nicely where the evap sits right now.
 

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Discussion Starter #14
I got everything on paper currently, mad a rough draft for the fittings needed. But won't know until I dig in and see where to mount it properly. I am looking for a location that is out of the way. Not near a heat source to heat the fuel and gets some cooling in the area. I think the rear panels under the rear bumper on either side will work. Left side being prefered.
 

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Discussion Starter #15
The other nice part is that the surge tank has a fuel pick-up so it will not start if mounted horizontal.
 

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How will the return be affected by this...

Meaning... since the fuel return is responsible for the venturi effect from the other side of the tank and you will have to Y the return line one going to surge tank and other going to the fuel tank itself. Will we lose the venturi effect from decreased fuel pressure. However, I think with a adjustable FPR you will still be able to main adequate pressure to retain the venturi effect.
So if you lose the venturi effect on the return then what exactly would happen?
 

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So if you lose the venturi effect on the return then what exactly would happen?
your fuel tank would only hold half a tank as a starter, it would also cause more need for a surge tank on the track as it would take less force to starve the tank pump.

Basically out tank is like 2 tanks with a center hump, the venturi pulls the fuel from the far side tank and brings it to the pump side tank so it can be used.
 

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Discussion Starter #20
your fuel tank would only hold half a tank as a starter, it would also cause more need for a surge tank on the track as it would take less force to starve the tank pump.

Basically out tank is like 2 tanks with a center hump, the venturi pulls the fuel from the far side tank and brings it to the pump side tank so it can be used.
That is correct. That is why I know a adjustable FPR will be critical to make this work. As well as the fuel return will have to be AN4/AN6 line to the surge tank to keep the pressure up from the metal hard line return. I will keep the feed line a AN 6 line and the output to fuel rail a AN 6 line. With a feed running from the tank to the surge tank and the return line running to the surge tank it should keep the surge tank filled all the time as well as keep the air out and back to the intank so it can be vented properly.
 
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