MyE28.com

Bav Ace wrote: Jan 31, 2012 12:31 AM The fuel pump in my car seized up last week and I have been looking into replacing it with an aftermarket fuel pump, specifically the Walbro 255lph.

I have been researching my options and like a few others on the board, I'm planning to delete the dual pump design and install a single in-tank pump. I also plan to modify the fuel pump carrier/sender to use 5/16” injection hose from the sender to the fuel filter. That leaves the issue of how to reduce the 12mm output hose to 5/16” at both ends of the in-tank output hardline. Others have addressed or are currently addressing this issue. I intend to attempt the following and wanted to get some feedback... good idea? bad idea?...let me know.

Details: Purchase two brass or stainless steel 3/8 to 5/16 reducing tube splices. The 3/8 side diameter of each must be reduced slightly to fit inside the 12 mm hardline. I was able to accomplish a test fit by chucking the fitting in a hand drill and using sand paper to remove the necessary material, which almost took longer to chuck up than reduce to the correct diameter. A lathe could also be utilized if available but my hope is to keep it simple enough that almost anyone can accomplish the modification.

This is a 3/8 - 3/8 splice I was using to test for fit


The reduced fittings could then be soldered or brazed into the hardline. The hardline may need to be shortened to accommodate the difference in lengths of the original in-tank pump and the upgraded one.



Note: The sanded fitting must be cleaned very well, especially if you intend to run both an in tank and in-line pump to ensure that small pieces of metal are not drawn into the pump...causing the original problem...rinse and repeat.

I am currently waiting for more parts to arrive but will update this thread as I progress