Truck fuel pump hanger

[Brass_Machine]

Finally going to be getting in the shop. Unfortunately it is not for something I want to do, but have to do. I have an 01 Isuzu Trooper I am trying to sell. The truck has sat for about a year after the starter gave up. I found a buyer who wants it, so we replaced the starter to get it running. It started fine but was spraying fuel by the gas tank. After trying to find out what was wrong, it was determined that the fuel pump hanger (in tank pump) had corroded. The screws holding the plate to the tank look like rivets. The hard lines coming out had holes in them.

Started looking everywhere for a replacement. Apparently getting hen's teeth would be easier. No used ones to be found. New costs about $450. Way more than I want to put into the car to sell it.

Spoke to the potential buyer about fabbing up a new one. Did some research online and found racers and high HP engine builders use custom billet ones with 2 or 3 pumps to support the high HP.

So I can do this but am left with some questions on the design. Since the new plate is aluminum, welding is out of the question for me. I don't have the resources for it. How do I seal up the hard lines coming out of the pump.

Here is the pump (new) I am trying to replicate:



I am going to do something like this:



I am pretty sure I have an idea for the line from the pump out. But the other hard line...

Any ideas or suggestions?

Eric

[awemawson]

Why can you not use 'bulkhead connectors' and pass suitable bundy tubing straight through them, using the connector as a support and a seal? The pump line will be under a few psi pressure, but the other return line will be under very little.

There is a fellow on YouTube who replaced his with a Bosch pump:

[Brass_Machine]

Thanks Andrew! That's just the search term I needed. Wasn't sure what those connectors were called!

[Pete W.]

Andrew,

Would it not be a good idea to put a Dowty seal on the bulkhead connector?  I know they're OK with hydraulic fluid but are they also fuel-proof? 

(I guess my calling them 'Dowty seals' shows my age!!!) 

[awemawson]

Should work nicely Pete, and even if others call then bonded washers, they're still Dowty seals to me

[John Rudd]

Andrew,

Would it not be a good idea to put a Dowty seal on the bulkhead connector?  I know they're OK with hydraulic fluid but are they also fuel-proof? 

(I guess my calling them 'Dowty seals' shows my age!!!)

Pete,
You are not alone.....I know them as Dowty too.....

[Brass_Machine]

Are we talking about these THINGS



Eric

[John Rudd]

Looks like it to me.....

And these....

[awemawson]

Yes basically an 'O ring' slightly fatter than the thick washer that it is bonded inside, allowing two flat faces to seal as I did in the modified fitting for my JCB 803

[Brass_Machine]

So I started to work on this.

This is the piece needed replicating:



Digging through my pile of aluminum, I realized I didn't have a piece that would fit the full circumference of the plate. Not only that, but my small mill could not cut the plate in one go... not enough Y axis. So I used a smaller plate and did the Gcode so I could cut it in two operations. Forgot the camera, so here is the mill cutting the second operation.

On the mill and jigged..



And let the machining begin!



Drilling the mount bolt holes



Finished piece



More to come...

[Brass_Machine]

I know it isn't perfectly round, but I tested it up. Plenty of meat to seal the gasket!

[AdeV]

It doesn't matter who you  make the chips for.... it's the making of the chips that matters!

Nice to see you making things again Eric 

[Brass_Machine]

Thanks Ade, yeah... it is nice to be in the shop again.

I threw the plate back onto the mill and bolted it down to the jig so I could drill out the holes for the bulkhead connectors.







Figured I would cut the actual fuel pump hanger off the old plate and knock up a quick mount for it on the new plate. Took some measurements and proceeded to hack the hanger off. Took a piece of 1x1.? aluminum and drilled some mounting holes in it. I had to offset them for 2 reasons. 1. the bolts would be going in on 2 sides and I did not want them to collide. 2. The original location of the hanger was slightly offset.







Of course, when I did my measurements, I was planning on grinding the hanger off. My Dremel took a dive, so I had to use a hacksaw. I did not take into account the .125" or so that I left behind in my using the hack saw. So, the pump was about .125" too high. Figured I could make a new mount, but decided to take the easy way and just make a spacer (didn't take pictures)

Here is the hanger mounted on the plate.



And finally, one of the bulkhead connectors to check clearance.





Now I am waiting on some parts while I figure out how to mount the electrical connectors...

[vtsteam]

Hey Eric.......yer makin' something!

When you get this baby done, just keep going and get that lathe bed switched over to the new one......

[Brass_Machine]

Hey Eric.......yer makin' something!

When you get this baby done, just keep going and get that lathe bed switched over to the new one......

The new one is on, need to align the headstock, make some taper gibs and install the extended cross slide... Then on to the CNC rebuild!

[Brass_Machine]

Here was my next problem. The power connector for the fuel pump:



It originally stuck through a pipe. If you look carefully, you can see the O ring that seals it. So, I cut it out, measured it and made a mount for it.

Found a piece of unknown quality of aluminum and chucked it up:



Then my phone started to die, so I was selective on taking pictures.

Here it is finished:



With the connector in place:



I also made a spacer for the pump itself. No pictures while making it because again, phone was dying. So I saved the battery for when I was finished.

So, here is how it stands now.





Have to take care of the fuel return line and one more connection. Parts arrive tomorrow to finish up.

Eric

[jcs0001]

Very nicely done.  Bye the time you are finished that module will be worth more than the truck.

John.

[RobWilson]

Nicely done Eric    very pro looking    ,,,,,,,,,,,,,about time you got your paws dirty again   






Rob

[AdeV]

That looks fantastic... I actually like the fact it's got flat sides, makes it look more professional in my opinion. Those fittings really help make it as well.

Nice work!

[awemawson]

Very nice Eric,

My only concern would be if that Ty-Wrap will stand up to immersion in diesel for protracted periods.

[AdeV]

Very nice Eric,

My only concern would be if that Ty-Wrap will stand up to immersion in diesel for protracted periods.

Unlike here, most American trucks don't run on Diseasel.... Eric mentioned a gas tank in the top post, so I presume this is a Petroleum Spirit powered vehicle...

[awemawson]

Same question though Ade. I've seen Ty-Wraps degrade and pop off on cable trays in oil refineries just from the vapours, never mind total immersion.

My choice would be a Jubilee clip in that position.

[John Rudd]

Stainless steel Ty- wrap for some added bling

[awemawson]

I have a gizmo called a 'Band-It' which would be ideal. Clamps a stainless band of any size.

http://www.band-it-idex.com/en/products/Band%20%26%20Buckle/Valu-Strap%20Band,%20Valu-Strap%20Plus%20and%20Valuband.html

[AdeV]

Same question though Ade. I've seen Ty-Wraps degrade and pop off on cable trays in oil refineries just from the vapours, never mind total immersion.

My choice would be a Jubilee clip in that position.

Agreed. It would probably dissolve faster in petrol than in diesel... although it does depend on the material. I'd have to go hunting to find what plastics aren't dissolved by hydrocarbons, and whether or not they make tie wraps out of them. But yes, in this case, I'd be inclined to use a jubilee clip. Or fab up a "split bracelet" to hold it, with a screw to hold the bracelet together.