wreckwriter
02-06-2011, 11:19 AM
Well, I've proved the theory: Lonnie's fuel system can be installed without dropping the tank. I did this install by myself with common hand tools. Much credit goes to Norm for coming up with the idea of cutting an access hole for the fuel pump bucket.
I'll post the steps in the order I did them and will include the pics I have. The pic quality isn't great but it's what I have. Please note that there will be no pics of the actual modified fuel bucket. Lonnie asks customers not to post those and, even though he never mentioned it to me personally, I will honor his wishes.
Pump is available at http://www.lonniesperformance.com/gtog8fuelsystems.htm All other parts were sourced at Summit, Pace, and McMaster-Carr. I use Aeroquip AQD hose and fittings, Aeromotive regulator and fuel filter. Lonnie needs your bucket to modify so be prepared to wait a couple weeks after you send it in. I bought a bucket off ebay so I wouldn't have to leave my tank open.
First, disconnect battery and then cut a fuel pump access hole. (see http://forum.grrrr8.net/showthread.php?t=11070 ). You can use an air nibbler like Norm did but I used standard aviation snips. Be prepared to cut yourself on sharp edges. There's a round indent you can follow. My hole ended up just short of 9" in diameter. Once you get the hole cut find some rubber trim for the sharp edges. I used http://www.mcmaster.com/#catalog/117/3739/=ax1hqk . It'll save your hands, trust me.
Next remove the factory electrical and fuel lines. The fuel connectors are a bitch. Search here for a thread where I was trying to figure them out. Once you get them off you can pull the pump. You also need to get the fuel line off under the car where it connects to the factory metal line (just forward of the tank, right side of car).
There's a big black retaining ring holding the pump bucket in. A punch and a hammer to remove; standard thread (lefty-loosey). Takes a pretty good bang to loosen it. A brass punch would be safer but I used steel.
When you pull the pump/bucket out be careful. There's a line that goes to the other side of the tank that must be disconnected (and reconnected later). There's also the fuel level float. Just take your time and wiggle it out by turning it various ways :) Installing the new pump is the reverse. Don't forget the line at the bottom of the bucket.
Next get the plastic line out of the way. I cut the end off on the bottom and dragged it out the top. Don't think it can come out intact. To facilitate this and the install of the new lines I loosened the front bolts on the fuel tank retaining straps.
Now its time to put in the new lines. I used -8 for feed and -6 for return. Install a straight connector on one end of each hose then slowly push them (the end without connector) into the space on the right side of the pump access hole (by the big grommet). Take your time and if at first they don't go, try a different angle. They will go through. Once they come out the bottom pull them through and connect the top ends to the new pump. Use 2 wrenches so you don't bust the plastic bucket.
Here's what it looks like (note: wiring is already done in pic, we haven't got to that yet in description):
http://i266.photobucket.com/albums/ii262/wreckwriter/2011-02-05_17-14-38_100.jpg
I'll post the steps in the order I did them and will include the pics I have. The pic quality isn't great but it's what I have. Please note that there will be no pics of the actual modified fuel bucket. Lonnie asks customers not to post those and, even though he never mentioned it to me personally, I will honor his wishes.
Pump is available at http://www.lonniesperformance.com/gtog8fuelsystems.htm All other parts were sourced at Summit, Pace, and McMaster-Carr. I use Aeroquip AQD hose and fittings, Aeromotive regulator and fuel filter. Lonnie needs your bucket to modify so be prepared to wait a couple weeks after you send it in. I bought a bucket off ebay so I wouldn't have to leave my tank open.
First, disconnect battery and then cut a fuel pump access hole. (see http://forum.grrrr8.net/showthread.php?t=11070 ). You can use an air nibbler like Norm did but I used standard aviation snips. Be prepared to cut yourself on sharp edges. There's a round indent you can follow. My hole ended up just short of 9" in diameter. Once you get the hole cut find some rubber trim for the sharp edges. I used http://www.mcmaster.com/#catalog/117/3739/=ax1hqk . It'll save your hands, trust me.
Next remove the factory electrical and fuel lines. The fuel connectors are a bitch. Search here for a thread where I was trying to figure them out. Once you get them off you can pull the pump. You also need to get the fuel line off under the car where it connects to the factory metal line (just forward of the tank, right side of car).
There's a big black retaining ring holding the pump bucket in. A punch and a hammer to remove; standard thread (lefty-loosey). Takes a pretty good bang to loosen it. A brass punch would be safer but I used steel.
When you pull the pump/bucket out be careful. There's a line that goes to the other side of the tank that must be disconnected (and reconnected later). There's also the fuel level float. Just take your time and wiggle it out by turning it various ways :) Installing the new pump is the reverse. Don't forget the line at the bottom of the bucket.
Next get the plastic line out of the way. I cut the end off on the bottom and dragged it out the top. Don't think it can come out intact. To facilitate this and the install of the new lines I loosened the front bolts on the fuel tank retaining straps.
Now its time to put in the new lines. I used -8 for feed and -6 for return. Install a straight connector on one end of each hose then slowly push them (the end without connector) into the space on the right side of the pump access hole (by the big grommet). Take your time and if at first they don't go, try a different angle. They will go through. Once they come out the bottom pull them through and connect the top ends to the new pump. Use 2 wrenches so you don't bust the plastic bucket.
Here's what it looks like (note: wiring is already done in pic, we haven't got to that yet in description):
http://i266.photobucket.com/albums/ii262/wreckwriter/2011-02-05_17-14-38_100.jpg