custom fuel system - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 28 (permalink) Old 01-06-2009, 06:34 PM Thread Starter
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custom fuel system

i did my fuel system completely custom. there isnt one part of the stock fuel system still on the truck.

i first removed all the stock fuel lines and HFCM. the front passenger fuel line from the filter housing to the head had to be cut for me to get it out easily. the driver side came out easy. i also had to remove the plugs in the back of the head. since i was doing it all i pulled the uppipe and y-pipe out to give me more room.

for the install, i used Earls 90* o-ring fittings on the front and and back of the heads. http://www.jegs.com/i/Earl's/361/949092/10002/-1
i then ran -6AN stainless braided fuel lines from the fittings on the front and back of the heads to the front to -6/-6 Ys. then from the -6 Ys to a -6/-8 Y. at the back of the -8/-6 Y i put a male/female -8AN fuel pressure fitting. then from the fitting i ran -8AN stainless braided down along the path of the stock system to the Airdog FP-150.

i mounted the Airdog using the brackets that came with the airdog kit. the Airdog kit came with -8 push connect fuel line and fittings, larger fuel pickup, the bracket to mount, and the electrical to hook it up. the directions that came with my kit were good.

in order to install the larger fuel pickup i had to drop the tank. i drained the tank first and then it was rather simple to drop it. i believe it was a 1 1/8" hole that needed to be drilled. i was going to put my pickup near the back but i do more than just drag race so instead i put it near the stock pickup.

after the pickup was installed i hooked up the fuel line that will go to the Airdog. this is also the time to cut the fill tube to install the return line. after the pipe was installed i hooked up the return line as well. then i put the fuel tank back in and ran the feed and return line to the Airdog.

as far as the electrical part goes, all i really needed to do was hook it up. i ran the wire harness up along the frame and mounted the relay near the battery. instead of having the trigger hooked up to the stock fuel pump(HFCM) power wire i ran it to a seperate fused switch.

that pretty much completes the install. so it goes like this. 1/2" ID pickup tube, -8AN push to connect fuel line from the pickup to the Airdog. from the airdog a -8AN push to connect line goes back to the fuel fill tube for the return. from the Airdog is a -8AN stainless braided line that goes up to a -8/-8 male/female fuel pressure port fitting. the fitting is attached to a -8/-6 Y to (2) -6AN fuel lines. those lines then go to (2) -6/-6 Ys. now there are a total for (4) -6AN lines. they then go to the front and back of the heads where they end with Earls o-ring 90* fittings.

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post #2 of 28 (permalink) Old 01-06-2009, 06:38 PM Thread Starter
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here is how the Airdog came from Dfuser.


















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post #3 of 28 (permalink) Old 01-06-2009, 06:44 PM Thread Starter
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HFCM and fuel lines compared to airdog and fuel lines

stock fuel line from HFCM to filter housing compared to -8 feed line




here's some of the parts i used that i got from Jegs

-8/-6Y and fuel pressure port fitting


with autometer sending unit


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post #4 of 28 (permalink) Old 01-06-2009, 06:51 PM
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looks like a lotta work there!

04 6.0, studs,dj fuel +,isspro gauges,sct by eric,4in silverline w/o kitty,HID's, and other odds and ends
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post #5 of 28 (permalink) Old 01-06-2009, 06:51 PM Thread Starter
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here is the airdog mounted



here's the FREE stainless braided and fittings that i used. i believe it is aeroquip

here is the -8/-6Y with (i believe)30* fittings and -6/-6 Y with same -6AN fittings

here are the -6AN lines wrapped with heat wrap for the back of the heads


-6 line and fitting connected to the passenger side rear of head

driver side front of head with line and fitting

passenger side of head with line and fitting

roughly where i was planning on putting the lines


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post #6 of 28 (permalink) Old 01-06-2009, 06:56 PM
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havent read through all of it yet, but im sure its a great writeup buddy!! good job! now hopefully when all the newbs ask us about our fully custom fuel systems we can just paste this link!!

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post #7 of 28 (permalink) Old 01-06-2009, 06:57 PM Thread Starter
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here is where i put the fitting for my fuel pick up

pickup installed


and while i was in there i harpooned the tank(it really do work good )


here's the airdog with the feed and return lines

the return line in the fuel fill line

the fuel feed from the pickup

here's the fuel pressure port fitting with -8/-6 Y

the -6 lines from the first Y to the (2) -6/-6 Ys


here it is completed


Garrett






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post #8 of 28 (permalink) Old 01-06-2009, 07:25 PM
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DUDE thats aLOT of work...... but you didnt have to duel feed the heads......

Jordan

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post #9 of 28 (permalink) Old 01-06-2009, 07:36 PM Thread Starter
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Quote:
Originally Posted by 6L strokin View Post
havent read through all of it yet, but im sure its a great writeup buddy!! good job! now hopefully when all the newbs ask us about our fully custom fuel systems we can just paste this link!!
i know, the original thread had a lot of info in it but it was too drug out.

Quote:
Originally Posted by blackcloudCTD95 View Post
DUDE thats aLOT of work...... but you didnt have to duel feed the heads......
no, i didnt have to but i wanted to be different. it works good too.

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post #10 of 28 (permalink) Old 01-07-2009, 04:07 AM
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Quote:
Originally Posted by blackcloudCTD95 View Post
DUDE thats aLOT of work...... but you didnt have to duel feed the heads......
No but now the heads have EQUAL pressure front to back and the rears will never starve




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