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Installing a bulkhead fitting through the fuel pump


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#21 Joe2Lmaker

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Posted 21 November 2008 - 03:52 AM

QUOTE (Warchild @ Nov 20 2008, 09:14 PM) <{POST_SNAPBACK}>
QUOTE (Joe2Lmaker @ Nov 20 2008, 06:55 PM) <{POST_SNAPBACK}>
There won't be any pressure testing for me until the North thaws out again.


Oh, there are ways.... there are always ways... blink.gif

True. I woke up this morning thinking about a way to do it. It would involve making an airtight seal for the top of the tank. Then, I could do a leak down test using compressed air. I already have a tester that would work.

"I woke up this morning thinking about it." ... I must be getting old!
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#22 dsmack

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Posted 21 November 2008 - 09:54 AM

No, OLD is when you wake up thinking about something, then can't remember what it was!

Excellent project, fun to follow along as you're solving the many challenges...

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#23 dcarver

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Posted 21 November 2008 - 03:05 PM

QUOTE (Joe2Lmaker @ Nov 21 2008, 03:52 AM) <{POST_SNAPBACK}>
"I woke up this morning thinking about it." ... I must be getting old!

Yep, when all you can do is THINK about it, you ARE old! unsure.gif

Be sure to fully pressurize the tank so we have a good test model and data. I think about 200 psi ought to do it! blink.gif
Seriously, great work and read..
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#24 CHRIS_D

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Posted 22 November 2008 - 05:14 AM

Great thread!!!! If this works which I think it will, is it possible to buy just this part of the Gen 1 fuel pump. I like this because I really didn't want to drill into the tank.
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#25 Canadian FJR

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Posted 22 November 2008 - 07:46 AM

I have the Gen I and really hope this works. Thanks for all your work and keep us posted.










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#26 Joe2Lmaker

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Posted 22 November 2008 - 08:36 AM

QUOTE (Canadian FJR @ Nov 22 2008, 09:46 AM) <{POST_SNAPBACK}>
I have the Gen I and really hope this works. Thanks for all your work and keep us posted.

Are you considering upgrading to a GenII?
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#27 Canadian FJR

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Posted 22 November 2008 - 12:40 PM

Nope, just want to add a cell.







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#28 exskibum

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Posted 22 November 2008 - 01:33 PM

QUOTE (Canadian FJR @ Nov 22 2008, 12:40 PM) <{POST_SNAPBACK}>
Nope, just want to add a cell.

I think the point is that this creative fix only works for Gen II owners. The reason is that on a Gen I, that extra nipple/line into the fuel pump body is already used as a return from the fuel rail to the tank in the Gen I fuel injection system. The Gen II's fuel injection system doesn't use a return line. Therefore, JTM is canabalizing a Gen I fuel pump body to use its return line nipple for the purpose of connecting the aux. fuel cell on a Gen II that doesn't need to use that nipple for the fuel return.

Question for the gurus: I guess if you wanted to get creative for a Gen I, you might run your return to a nipple on the aux. tank and then go ahead with what JTM has on the drawing board for your feed line from aux. tank to main tank. Any reason that wouldn't work (so long as the aux tank has a return nipple or (maybe) a Tee in the feed line)?


Interesting thread and project, JTM! Wishing you success on this very sanitary looking solution.

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#29 madmike2

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Posted 22 November 2008 - 06:51 PM

QUOTE (exskibum @ Nov 22 2008, 01:33 PM) <{POST_SNAPBACK}>

Question for the gurus: I guess if you wanted to get creative for a Gen I, you might run your return to a nipple on the aux. tank and then go ahead with what JTM has on the drawing board for your feed line from aux. tank to main tank. Any reason that wouldn't work (so long as the aux tank has a return nipple or (maybe) a Tee in the feed line)?

IIRC, the return line is pressurized.
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#30 Gramps

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Posted 23 November 2008 - 07:56 AM

Very cool Joe, looks like you're making progress.
If you need heat for your garage I have a 110,000 BTU Kerosene torpedo type heater I'm not using that would keep you toasty. cool.gif
Also, if you could use a extra set of hands (albeit uneducated ones smile.gif ) let me know.

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#31 radman

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Posted 23 November 2008 - 08:38 AM

QUOTE (madmike2 @ Nov 22 2008, 08:51 PM) <{POST_SNAPBACK}>
QUOTE (exskibum @ Nov 22 2008, 01:33 PM) <{POST_SNAPBACK}>

Question for the gurus: I guess if you wanted to get creative for a Gen I, you might run your return to a nipple on the aux. tank and then go ahead with what JTM has on the drawing board for your feed line from aux. tank to main tank. Any reason that wouldn't work (so long as the aux tank has a return nipple or (maybe) a Tee in the feed line)?

IIRC, the return line is pressurized.


Yes, it is. But it could be done by teeing into the return line, with a shutoff valve isolating the line to the aux tank, and it could not be used while the bike was running.
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#32 Joe2Lmaker

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Posted 23 November 2008 - 10:50 AM

QUOTE (Gramps @ Nov 23 2008, 09:56 AM) <{POST_SNAPBACK}>
If you need heat for your garage I have a 110,000 BTU Kerosene torpedo type heater I'm not using that would keep you toasty. cool.gif
Also, if you could use a extra set of hands (albeit uneducated ones smile.gif ) let me know.

Sounds good. I'll call you when I'm getting ready to pressure test it. download.gif Bring your helmet, and see if Wicked Webby will let you borrow a bullet proof vest. grin.gif


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#33 Joe2Lmaker

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Posted 23 November 2008 - 02:17 PM

Here is the fitting I need to make. I rotated the hex 20 degrees on the model. The fuel line should drop right into the pocket in the heat shield.



Some of the features don't add anything to the fitting's function, so it could be simplified to this:





Now, this would be the razzle dazzle solution:


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#34 Joe2Lmaker

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Posted 06 December 2008 - 10:00 PM

For those of you who yawn when you see a screen shot of a CAD model:






The new fitting is finished. Now I need to make a seal/ fitting for the tank's filler neck (for the pressure test).
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#35 worldbound4now

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Posted 06 December 2008 - 10:17 PM

clean, sweet, custom mod. Reminds me of my nipples.
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#36 Joe2Lmaker

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Posted 07 December 2008 - 11:33 AM

The parts store was open this morning, so I could get a little further with the install.

I decided to reuse the "O" ring:





This is what It looked like right after I heard the satisfying "click" of the snap locks grabbing the new fitting:



Here a shot showing of the snap locks holding tight:



I looks like I got the orientation I was after:





Everything clears the heat shield now:



There is no reason this wouldn't seal as well as the original fitting. Do I really need to pressure test it?


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#37 Canadian FJR

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Posted 07 December 2008 - 03:59 PM

Very nice work. I need to find a way to do a bulkhead on my 2003 without drilling the tank.






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#38 CHRIS_D

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Posted 07 December 2008 - 07:56 PM

So Joe when is your fuel pump modification kit going to come out? I will take one, thank you. smile.gif Oh yeah I can also host a group buy for you. laugh.gif laugh.gif
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#39 Capt. Bob

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Posted 08 December 2008 - 05:13 AM

Slick, absolutely slick.

As far as a pressure test, do it in the field.

What's the worst that could happen? unsure.gif
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#40 Joe2Lmaker

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Posted 10 December 2008 - 03:54 PM

QUOTE (CHRIS_D @ Dec 7 2008, 09:56 PM) <{POST_SNAPBACK}>
So Joe when is your fuel pump modification kit going to come out? I will take one, thank you. smile.gif Oh yeah I can also host a group buy for you. laugh.gif laugh.gif

I don't think there are too many GenI fuel pump flanges to be had. I sorta lucked out (at madmike2's expense).
So, if someone else wants to do this it'll mean modifying the GenII fuel pump flange. It could be done, but it involves cutting a taper to a precise depth to free up those lock tab features.

Even though my fitting has no check valve to overcome, and even though the flow size is considerably larger than the GenI return fitting, it's too small for gravity feed.

Those are the cons.

On the other hand... (in my best Tevye impersonation)

I did make an extra one...

And this is what my backyard is looking like...



As Rod Blagojevich might say; "maybe we could work something out"

Let's see... someone in a year-round riding season, with a auxiliary fuel cell, a GenII FJR, an extra GenI fuel pump flange, a fuel pump from their auxiliary fuel cell...

:"call me" smiley:

QUOTE (Capt. Bob @ Dec 8 2008, 07:13 AM) <{POST_SNAPBACK}>
What's the worst that could happen? unsure.gif

O.K. ... O.K.

The pressure test is scheduled for Sunday. rolleyes.gif
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