Ksths2

This maybe be lengthy…….Some of you know that I’m slowly working on a new setup for my 2002 C5, a new LS 408, E85 fuel, A&A YSI blower with possible of +20# of boost, guessing at +1000rwhp.

And now my latest thing is I’m trying to get a fuel system that will still work with E85, using the factory 24 tooth/GM computer, gauges etc. and would like to keep all that including having the gas gauge work. So far all I have for it is a Magnafuel EFI boost ref fuel regulator, big fuel rails, ID1300 injectors and that’s it. Other than my used non-E85 compatible Lingenfelter high-flow pump I’ve had in the car with the previous setup. Other than that it’s a stock 2002 C5 fuel system.

I originally was told about Lonnie at LPE had my all my answers but after talking with him his system had me worried it might not be enough to support my 1000rwhp on E85 goals with only using a 255 pump for normal and only one 340 pump when the boost kicks in.

A&A didn't have anything big enough to use with E85.

So then I found FORE Innovations which was great but their triple pump setups only worked with 2003 gas tanks (pump inserted from the top of tank) which super sucks considering they have exactly what I need!!! I emailed them back to find out if it’s as simple as installing the newer 2003 style tank in my car and then were good to go but heck I can’t even find a place to get a real 2003-2004 tank, Ebay shows a few but the pics actually show 97-2002 style tanks so not even sure if that’s an option……..

So then I was steered towards RSI and they basically said they haven’t done a system for a C5 in years, good luck.

So then went to Squash, they don’t have a kit for my car but maybe can put together a system for me, TBD on that.

Anyway I’m just frustrated and trying to do this right the first time but its been a struggle and hopefully you guys can help me out?

Thanks a lot in advance!

cmiller8006

Hang in there, there are a few on here that should be able to get you set up. I have an 04 and went with the aeromotive drop in eliminator set up. Seems like it will be good, not sure if they make one for the 02's or not.

Shoaf85

My vote would be do keep doing a little research then build your own system as I and many others in here have. The most common approach and the one I would recommend is to retain the small single pump in the tank for normal driving and what not. Then plump a secondary/auxiliary pump such as a Magnafuel external pump that is ran off of a boost referenced hobbs switch.You can have the secondary pump Y into the feed line just before the rails and then use the same return line setup that you have now (if I read that correctly in the first post).

FWIW I am currently running the LPE non E85 walbro in tank (was in the car when I bought it) with a Magnafuel external pump (activated by a 2psi switch) Y'd together with the factory feed line just before the rails. Return is from rails to boost referenced MagnaF regulator the from regulator back to the tank via factory return port. I installed a bulkhead fitting in the tank for the feed on the magnafuel pump but an easier solution is to buy the ECS fuel tank ring which incorporates a feed line fitting into the side of it.

Ksths2

FYI, Will @ RSI is still trying to figure it out for me, I found out that they are the guys who make the original dual pump bolt in billet bracket for 97-02's - but not sure if they still make it etc. TBD.

Shoaf, I've found a couple thread that guys on here that have used the stock fuel plate that bolts into the tank and basically made there own in tank system using hose clamps, 2 pumps and a "Y" but I'm confused how that would work with still running the small steel lines come from the pumps to the outside of the tank, to me it looks like a major restriction? I like your suggestions and by your signature 5.62@125, your setup is workin but not 100% sure if I know what your system would look like, i'll re-read your post 50 more times and maybe it'll click lol

Still learning a lot about the fuel stuff for our cars but the more I dive into it the more confusing it is lol

Shoaf85

I can go into more detail with how the setup is routed later when I get a moment. It does all sound a little confusing but actually seeing the system in pics or in person really puts everything into perspective and simplifies how it's setup.

chris308

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Shoaf85

So I'm guessing have you already converted to a return style fuel system. Running the aftermarket regulator requires that. If that's the case then a lot of the work is already done.

C5 Pete

I'm helping a friend doing a 346/YSI E85 build.

He has the 255 in tank pump with the hot wire kit.
He also has the holley twin pump externally set up with a dedicated line running to the front of the car. That is also on a hot wire kit.

In the engine bay, the feed line from the Holley pumps and the factory line come together and go to the fuel rails.
Off the fuel rail the line goes to the regulator and then back to the tank.

It's all boost referenced and should support 1000 hp.

He can describe it better than I can, but he's not much of a poster on here.

Ksths2

Shoaf, no mines an 02 so it only has a return from the stock filter/regulator on the frame in the back but that will all be gone with the new fuel system - Yes I’m converting it to a return style system I just need to run the lines but not sure what to get. Lonnie says -8an is good enough for the supply and -6an is good for the return but personally seems small for E85 but maybe not?

Capthuff, good info.

After looking at all the pumps etc it looks like the AEM 320 50-1200 (Green pump) are really good? So I’m thinking of piece'ing my own system together like you guys doing. What about this idea?
Run 1 of those AEM320 pumps in tank for normal driving then have 1 or 2 more of those in the tank as well and they turn on via hobbs switch that's in the intake? And then run the ECS ring out of the tank and the stock supply line out and then Y them together and have 1 big line going to the back of the rails?
And obviously a return back to the tank.
BTW, will the stock transfer from tank to tank pump work with E85? I'm sure it wasn't designed for it.... What about eliminating the passenger side tank completely since weight is a concern for my heads up class anyway?

C5 Pete

Yeh... Remove the pass side tank. With tuning software, you can make the fuel gauge read only the one tank. It holds about 9 gallons, so, that should be plenty.

Also, I forgot to add that my buddy uses the ECS ring too. It's a real slick piece.


What class are you running?

Ksths2

Cool I didn't know you could eliminate the pass tank, that helps. Never heard of anybody doing that before but always wondered
The class is street legal heads up, no back half cars, mufflers, dot tires, must be licensed and insured. This class travels to 3 tracks and is a ton of fun. To win usually Et's are 5.70's 1/8 mile

Milan

Walbro 450 in tank, Bosch 044 external. BAP on the Bosch

1300 cc injectors will be a stretch....up your fuel pressure a ton, like 80 psi base

Rkreigh

do you like the Bosch 044 better than the magnafuel 4303

I'm considering this same setup. need to get to 1k at the tire on e85 with 127 Bosch FIC injectors with direct injection meth on top

not too worried about it being "meth dependant"

car will have a flex fuel sensor so the meth is there when running on pump gas and for a bit of "insurance fuel" in case the 127 FICs aren't big enough

where do you all buy your check valves and fittings and braided line?

I'm looking for the nylon braded stuff that is light and teflon lined or whatever fuel hose works best with e85 and meth

love to do "hard chrome lines" for a bit of "funny car look" under the hood. should be trick!

dougrodriguez

Kinda happy this thread is here. I've been trying to spec a system out myself forbade 2003+car that I run. I was gonna do a intank Walbro 450 e85 compatible with what I was thinking a magnafuel fuel pump external. I was gonna run -8 to the rails and utilize the factory lines as returns. Wanted to run the car purely on e85 with a flexfuel sensor on a trucks pcm all enabled to have seamless fuel transition. Kinda new territory on the flexfuel seems like vengeance racing figured it out. I wanted to be first c5 on flex oem lol jk

JDS99

What makes you recommend this out of curiosity?

80psi base is a LONG way away from optimizing those pumps with that size injector. Not to mention the 450 noses over hard at 80+psi, as the overpressure relief starts opening. With no BAP on the 044, peak system output is right at 60psi. Slightly higher with BAP on. So if he's running 20psi, technically 40psi base on a boost referenced regulator would be generate highest potential of the system. Beyond that and it's diminishing returns, as the injectors will outflow the pumps.

Op, I would start at 1600+ cc if you want some headroom left in the injectors on E85 at 1000whp. Then just make sure the pump output supports what you need at desired fuel pressure. We had a spreadsheet posted to help with this a while back, but it was pulled because of too much drama. If you want to shoot me a PM i'd be happy to share.

C5 Pete

That thread was great. Too bad it's gone.

The drama in this section has gotten way out of control...

chris308

what grade fuel filtration is used for E85; 10, 40, or 100 micron?

Milan

The Bosch 044 is still the high pressure king, especially with a BAP to it. Those magnafuel pumps are overrated to all ****, they don't work well at high pressure.

Walbro 450 does nose over a ton at 80 psi but it still greatly outflows an LPE pump.

1600 cc injectors are not really an option because they are only good to 5 bar. 2000cc CNG injectors are less than ideal too because they swell when used with E85. That leaves the 127's with high fuel pressure.

Shoaf85

I disagree with the magnafuel comment. My brother uses one on his 4cyl race car with a base psi of 45 and runs 50+ lbs of boost on a boost referenced system of course, however it is the bigger pump than the 4303 . Never has had any issue with unstable fuel pressures at 1200ish hp and around 100lbs of fuel pressure.

cmiller8006

10 micron filter.