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Had a setback on the fuel system. Apparently I can't get a stock replacement tank with baffles for an in-tank pump. They're listed, but when ordered they e-mail saying they don't know when they'll get one. So the plan is to use a 3L surge tank with 2 AEM 400's. I'll use the original tank with an EFI style sender/hanger and a lift pump to feed the surge tank. Question is what E85 safe pump do the guys with surge tanks use? I was thinking about just stripping one out of the fuel pump module of a flex fuel Silverado/Sierra at the U-pull it yard. I'd like something reliable. No Spectra crap if possible. On a side note, has anyone ever used the blocks of fuel cell foam in a factory steel tank to build a sort of baffle around the fuel pump? Stuff is kind of expensive and not so sure it wouldn't get sloshed free in the tank. This is all on an early 80's GM steel tank. So there's a fairly small opening to work through.
My tank has a sump from years ago when it was carbureted. I run a -12 from the sump and gravity feed a surge tank (located in front of the fuel tank/behind the rear end) that has twin AEM 380s in it. I think there labeled as 400s now. A -8 comes off each pump to a massive spin on fuel filter housing then a -10 comes off the filter housing and goes up front. One pump runs until I’m in boost then the other kicks on. F2i regulator and I can’t even tell when the second pump kicks on.
With my last couple car I found adding a sump to the factory tank with 3 one inch holes in the tank before welding on the sump works pretty well with sloshing. Then I just run the aem pumps external. One all the time and one at 10 psi boost . Seems to be less complicated than the surge tank setup. And I still have my factory guage
.......On a side note, has anyone ever used the blocks of fuel cell foam in a factory steel tank to build a sort of baffle around the fuel pump? Stuff is kind of expensive and not so sure it wouldn't get sloshed free in the tank........
I just did this for a buddy's car I am working on. It has a 20"Wx17"Dx10"H fuel cell with a fuel level sending unit towards the front of cell with a float that swivels up towards the rear. I used the blocks to build a "U" around the float with the open end towards the sump to help reduce the side to side and rear to front sloshing. The key to preventing the foam from dislodging and floating around is to make the total length of blocks several inches longer than the wall they're going up against, so you have to compress each piece slightly to put it in place.
I used the ATL yellow foam since fuel cells is their main business and it was the only one that had a heavy emphasis on it being E85 safe. A little pricey at $58.
What size do you guys use for a return with the dual 380/400’s? Thought about PWM the first pump to keep fuel temps down. And then have the second on under load. It’s a daily driver about 9 months a year.
What size do you guys use for a return with the dual 380/400’s? Thought about PWM the first pump to keep fuel temps down. And then have the second on under load. It’s a daily driver about 9 months a year.
I just did this for a buddy's car I am working on. It has a 20"Wx17"Dx10"H fuel cell with a fuel level sending unit towards the front of cell with a float that swivels up towards the rear. I used the blocks to build a "U" around the float with the open end towards the sump to help reduce the side to side and rear to front sloshing. The key to preventing the foam from dislodging and floating around is to make the total length of blocks several inches longer than the wall they're going up against, so you have to compress each piece slightly to put it in place.
I used the ATL yellow foam since fuel cells is their main business and it was the only one that had a heavy emphasis on it being E85 safe. A little pricey at $58.
Has he put some miles on that setup? I thought about doing the same thing in the stock tank. Figured even wedging the foam in, it may come loose.
I can sump the stock tank fairly easily. Just need a rubber flap to hide it from the back.
I'm still working on the car, getting ready to make the transition to E85 with all new PTFE hose. It has dual AEMs with the pumps Y'd into a 10an feed, then Y'd to 8s for each rail and a 8 return. I've probably put about 50 miles on the car with the foam but no hard launches or cornering. Certain they will not come loose. When I do the hoses, I plan to open up the pre-pump filters to see if there are any foam shavings. Surprisingly, there weas none when I cut the blocks to size.
Ordered a sump with 3/4 NPT. Want to feed the pumps with -10 lines and most sumps had 1/2 NPT fittings. Going to try to gravity feed them. We’ll see when the sump and pumps get here. This setup seemed the simplest and lightest. This thing is a behemoth. So light is good. I’ll update the thread when it’s sorted out.
I used the factory 90's 5.0 fuel pump as my lift pump. Came with the new fuel tank. Been working great with E85 for several years now. (though I usually blend it down around 60-70%)
I use -6 to filtered feed with the E85 sensor inline to the surge and return back to the OEM tank with a -6 as well. I run the regulator at the surge tank. Then the 2 AEM 380s plumb to the regulator with a -8 single line dead headed to the factory rail up front. Id suggest running them staged. Mine def get warmer than I'd like on long cruises. Bit of a mess but it works!
Last edited by Forcefed86; Nov 12, 2021 at 08:03 PM.
I used the factory 90's 5.0 fuel pump as my lift pump. Came with the new fuel tank. Been working great with E85 for several years now. (though I usually blend it down around 60-70%)
I use -6 to filtered feed with the E85 sensor inline to the surge and return back to the OEM tank with a -6 as well. I run the regulator at the surge tank. Then the 2 AEM 380s plumb to the regulator with a -8 single line dead headed to the factory rail up front. Id suggest running them staged. Mine def get warmer than I'd like on long cruises. Bit of a mess but it works!
That's the same surge tank I had in my cart till the whole fuel tank debacle. It was 3L and has ORB fittings. Looked like a decent deal for $50. With any luck the sump will gravity feed the pumps and the PWM from the goldbox will keep the fuel cool.
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E85 surge tank lift pump 
