Fuel System Sizing for 1000 hp?
Thread Starter
Staging Lane
Joined: Nov 2022
Posts: 62
Likes: 12
Fuel System Sizing for 1000 hp? Just making a list of everything I need to finish my turbo build. honestly expecting max like 700 - 750 wheel in a big truck (14 bolt 4l80e) so like 925 hp at the crank
Living in Ontario Canada they just mandated that by 2030 all fuel will have 15% ethanol. So I've been doing my calculations around 20% ethanol content which brings me to my first question.
I expect ethanol % variation at different stations so will be running a flex fuel sensor. How much does the stock flex fuel sensor support or should I just get the summit high flow one?
The current plan is a single 450lb walbro into 5/8 (-10an) stainless hard lines into a diesel 2-10 micron filter into the regulator, with a 1/2 (-8an) return line. I'll have a short run of flex from the regulator to the rail to account for any engine movement.
Is a single 450 walbro a good Idea? Should I use my current 255 walbro with a 2nd 255 walbro?
Would I be able to get away with -8 feed and a -6 return? Does it matter if my feed turns to a -8an right at the regulator? Could I run a -10 feed with a -6 return?
Should I just be using flex line instead of 304 stainless coil?
Almost forgot, What do people think of the knock off Ebay walbro pumps? Sloppy mech seems to like them but.... BTW the 255 I have was purchased through summit so should be legit
Thanks Guys
Living in Ontario Canada they just mandated that by 2030 all fuel will have 15% ethanol. So I've been doing my calculations around 20% ethanol content which brings me to my first question.
I expect ethanol % variation at different stations so will be running a flex fuel sensor. How much does the stock flex fuel sensor support or should I just get the summit high flow one?
The current plan is a single 450lb walbro into 5/8 (-10an) stainless hard lines into a diesel 2-10 micron filter into the regulator, with a 1/2 (-8an) return line. I'll have a short run of flex from the regulator to the rail to account for any engine movement.
Is a single 450 walbro a good Idea? Should I use my current 255 walbro with a 2nd 255 walbro?
Would I be able to get away with -8 feed and a -6 return? Does it matter if my feed turns to a -8an right at the regulator? Could I run a -10 feed with a -6 return?
Should I just be using flex line instead of 304 stainless coil?
Almost forgot, What do people think of the knock off Ebay walbro pumps? Sloppy mech seems to like them but.... BTW the 255 I have was purchased through summit so should be legit
Thanks Guys
Last edited by Jacob VH; Nov 10, 2024 at 01:47 PM.
You are going to get a bunch of different opinions on what fuel pump setup to use, so I won't touch that with a ten foot pole. However, the flex sensor situation has one correct answer. Use a factory style sensor in a bypass mount. This allows whatever amount of fuel the sensor will flow to go through it, while the rest of the fuel simply runs through the bypass section of the mount. Use a billet style mount from a reputable source and it will have no problems. The ones that are cobbled together from Y blocks and other fittings are going to leak from somewhere, and in the case of some cheaper ones, leak from everywhere.
Banned
Joined: Nov 2024
Posts: 10
Likes: 5
For your turbo build aiming for 700-750 whp with a 14-bolt and 4L80E transmission, your fuel system needs to be properly sized to handle the power and ethanol variability, especially with the move to higher ethanol content. You might consider
Flex Fuel Sensor
The stock flex fuel sensor is typically limited to around 1000-1500cc of fuel flow, which is usually fine for most builds under 700hp. However, since you’re targeting 925 hp at the crank (around 700-750 at the wheels) and using a significant amount of ethanol, you may exceed the stock sensor's capabilities. If you're expecting fluctuating ethanol content (as is typical with flex fuel), upgrading to a higher-flow sensor like the Summit or another higher-capacity sensor might be a good idea to ensure accuracy and reliability as you reach higher fuel demands.
Flex Fuel Sensor
The stock flex fuel sensor is typically limited to around 1000-1500cc of fuel flow, which is usually fine for most builds under 700hp. However, since you’re targeting 925 hp at the crank (around 700-750 at the wheels) and using a significant amount of ethanol, you may exceed the stock sensor's capabilities. If you're expecting fluctuating ethanol content (as is typical with flex fuel), upgrading to a higher-flow sensor like the Summit or another higher-capacity sensor might be a good idea to ensure accuracy and reliability as you reach higher fuel demands.
Thread Starter
Staging Lane
Joined: Nov 2022
Posts: 62
Likes: 12
Can I get away with a -8 feed -6 return?
if not can I get away with a -10feed - 6return
it would save me a ton of money on a fuel regulator
do people like stainless for hard lines?
Interesting. The original intro post by "currency" appears legit, but all subsequent posts read as a chatbot. I will take a wild guess that a real person may be running posts through chatgpt or something to come up with answers.
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Why mess with the 425 walbro when they have the 525lph hellcat pump for a similar price? I'd look at those if that's the route you def. want to go.
I'm not a huge fam of either as they are amp hogs and don't do as well at elevated "boosted" fuel pressures compared to other pumps like the inline AEM400. At say 70psi+ the AEM400 out performs the 525lph pumps in my experience. I also hate intank pumps with a passion as they are pain in the butt to access if needed. I'd setup a surge tank with intank oem style pump for reliability filling the surge. Then have the surge feed a single AEM400. You can add another if needed super easy down the road.
I've made a solid 600whp with a single AEM400 on E85 with 14.6v. I've seen over 1200whp with 2 AEM400's plumbed well w good voltage. Usually need 3 of the "walbro style" in tank pumps and 75amps or something ridiculous to do the same.
I'm not a huge fam of either as they are amp hogs and don't do as well at elevated "boosted" fuel pressures compared to other pumps like the inline AEM400. At say 70psi+ the AEM400 out performs the 525lph pumps in my experience. I also hate intank pumps with a passion as they are pain in the butt to access if needed. I'd setup a surge tank with intank oem style pump for reliability filling the surge. Then have the surge feed a single AEM400. You can add another if needed super easy down the road.
I've made a solid 600whp with a single AEM400 on E85 with 14.6v. I've seen over 1200whp with 2 AEM400's plumbed well w good voltage. Usually need 3 of the "walbro style" in tank pumps and 75amps or something ridiculous to do the same.
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