I might be overthinking this, so bear with me.

I will be upgrading my fuel 2011 Sierra to a return fuel system. Plan is 10an from tank to Y, 8an from Y to rails, rails to regulator, and 8an back to tank. The tank is the challenge.

I have the stock Denali/FF fuel module. Truck is 6.2L, .005 over, GPI ported heads, GPI stage2 truck cam, LT's, and D1SC pushing 12-14psi. I'd imagine it's probably making 450hp NA, so I should probably build enough fuel system for 1000-1200(?) for E85, safety and headroom further down the road? All that being said, I'd like to be able to treat the truck as stock- be able to get down to 1/4 tank or less, not worry about slosh starve on hard launches or inclines under 1/2 tank. I'd also like to keep factory evap in place. The factory pump sits in between 1/2 and 2/3 of the length of the tank towards the rear.

Option 1- New fuel bucket, install racetronix 2x525 and drill 10an feed bulkhead in hat, return through OE supply. Use return and/or venturi off return to pull from rear of tank to ensure bucket is full. Maybe fab up a shroud to make bucket 'taller' in tank.

Option 2- Snow Performance double or triple hat- already has 10an feed and 8an return, Evap, but no bucket. I feel like this would cause starving issues below 1/4 tank even with the generous sized shared pickup mat (hydramat?), and no bucket to cool pumps. Could probably repurpose OE bucket for it?

Option 3- Atomic Fabrication Internal Surge tank- takes care of most everything but I still need to contact him about evap. Most expensive route.

Is 2 450 or 525s with 1 of them hobbes activated enough, or do I need to go 3 450/525 with 2 boost activated? Truck is a daily so I'd like to keep it as 'civilized' as possible. Appreciate all suggestions, experiences, and criticisms.

 

2 pumps will be enough.

You might be able to fit 2 450s in the stock bucket. I did in a subaru bucket I modified

10an is ridiculously large for fuel line.

 

Roger. I think you're right- even with E85 I should be good with 2 for now. I could even run a couple 535's with a check valve outlet adapters.

My thought process on 10an is most of the aftermarket hats have 10an for feed, allows more headroom if I upgrade from the D1SC or go turbo, and dual 6an lines into a 10 should flow more volume than into 8an, while less pump stress/amp draw. Am I misguided?

 

If ypu size your injectors big enough to get your horsepower goal at a lower base pressure say 43 vs 60 ypur pumps will go alot further. With less amp draw and more lph

I run 2 450s through a single -6 feed and return with e on a turbo 5.3 at 20psi and fuel pressure is never an issue.

The bigger the line the better I guess but personally would find running -10 line obnoxious. But the subaru also doesn't have room like under a truck

maybe a short run of 10 to a filter with 8 out would flow more than enough

 

Running ID1050's right now. I may play around with pressure in the tune once I get the motor back together. At this point, piecing together a list to basically mimic the Racetronix dual pump assembly but with 6an ptfe feeds into a -10 bulkhead through a factory hat.

I'm only at 12-14psi with a 6.2 on the factory E85 pump/lines. I'm overbuilding everything for future growth and due to horrible luck I've had in other areas of the build. I am not kidding that I'm blessing the truck/engine to cast out any bad juju before the next 'first start'.

My plan currently is to go 10an from tank through filter to Y, and 8an from the Y to rails and all the way back to tank. If I end up with starvation issues under 1/2 tank, at least it's already set up for Atomic's surge tank I guess.

 

You don't need a -10AN feed line. You can certainly install one, but a -8AN will be more than enough.

 

Seeing a pattern here. Guess I'll stick with -8 for feed/return.

 

My car will eventually be over 1000 RWHP, and I'm sticking with -8AN.

 

You can also get a simple $30-50 cheap surge tank and not those ridiclious specialty options you listed that are 10x more money than they are worth. keep stock pump and electronics. fill surge tank wiht OEM pump. Then use aftermarket pumps plumbed to surge tank.

 

I'm all ears. I don't mind saving a buck.....What would the advantage to surge tank versus a sump kit like this from Summit?

https://www.summitracing.com/parts/bdd-1050330

Looks to be a similar style sump to what DSX offers for auxiliary fueling, less fabbing and time, and I could run a Magnaflow 4303 on a hobbes switch. I like it kills 2 birds with 1 stone, creating a feed where all the fuel is going to go on a launch and a return point.

 

Lots of benefits. Cost is the main one.

 

Im using a surge tank i got off ebay with staged 450s in it. It was cheap and has worked flawless. Few of my buddies switched to it after seeing mine.

 

Great setup for an OEM tank if you don't want the hassel of isntallign a sump and want to keep all the handy OEM features. I prefer external pumps. HArd to bet the AEM400's. They aren't amp hogs like the walbros and the performance/flow doesn't plumet as pressure goes up like the walbros. Stock pump and 2 AEM400s plumbed decently have been 183mph at 3100lbs on pump E85. They flow more than most will ever need.

 

Doing the math if it's correct, if 2 pumps are pushing 800lph, and my truck is slow AF and I'm in boost for 15 seconds, I'd need 3.33 liters not accounting for the lift pump constant fill or return. So I'd probably want a 3L?

Basically run the factory pump to fill something like this below. Dual inline pumps off lowest ports, 1 switched for X psi to rails, afpr return to surge tank, and surge tank return to fuel tank.

 

I run one similar to this

 

Did either of you have to modify your tank other than adding a return line port from surge tank to gas tank?

Curious if In need to add a line to the breather so when I fill up with gas it doesn't click off constantly or early.

 

I run a fuel cell

 

No, no other mosifications necessary.