B&D Racing's Mason Rowland...
B&D Racing's Mason Rowland lowers Fore Precision Works' Dual-Pump Fuel Tank Manifold System (PN 0037-015; $425) into the fuel tank of Manny Huerta's '04 Cobra. Yes, we've reviewed Fore's "fuel hats" (the popular name for the all-billet pump carriers) in past issues. The hot newness in this upgrade is the stock-fuel-line adapter (the black fitting near Mase's left hand) that enables '99-'04 New Edge owners to upgrade fuel pumps without a complete change of lines (unless big-time horsepower warrants converting the factory's non-return fuel-delivery system to return-style).
Many of us live and breathe through modifying our Mustangs. Seriously, the hobby truly is a way of life for hardcore 'Stangbangers. However, we realize that despite the desire to go for performance gusto in one fell swoop, economic concerns oftentimes dictate that certain upgrades be made in stages.
We've communicated many times the importance of having a fuel system that is capable of supporting the big-time horsepower (more than 700 hp at the feet) and torque that many enthusiasts aspire to in street-driven, pump-fueled EFI Mustangs. For '99-'04 'Stangs specifically, all roads ultimately lead to doing away with the factory's fuel plumbing and installing a return-style fuel system (where the primary fuel line is run forward from the tank, split into two separate lines that feed gas to each fuel rail independently, and then returns it to the tank via a line that exits a bypass regulator).
Return-style fueling guarantees an engine has a continuous supply of constantly flowing, evenly pressurized cool fuel. On supercharged Ponies, it has proven to be the best way to ensure the engine is getting enough gas when the hammer is dropped and boost increases.
Removal and replacement of...
Removal and replacement of an '86-present Mustang's in-tank fuel pump (or pumps) is not difficult, and can be accomplished in the driveway, provided you have sufficient means of safely raising the back of the car and the basic tools that are required for lowering the tank. Manny's car arrived at B&D with a full tank of fuel, some of which had to be removed. A "speed siphon" like the device that Mase developed (using an old Vortech T-Rex fuel pump, some rubber fuel line, and a 12-Volt power source) makes draining the tank a quick-and-simple deal.
In our opinion, when you're going after the big, big steam, cost should not be cited as a reason for pushing fate with the factory fuel system. However, we do understand how crucial wise financial choices are these days, so we were happy to receive word of two new parts from Fore Precision Works-a billet, dual-pump fuel hat (PN 037-015; $425) with an adapter that allows retention of the stock fuel line (PN 037-022; $55). The setup brings budget-minded New Edge owners a step closer to hopping up their stock fuel system for moderate power increases, and then easily upgrading to a full-on aftermarket setup-AN -8 line, AN -6 return, regulator, and so on-later (i.e., when the funds are available to do it).
Los Angeles-area '04 Terminator owner Manny Huerta aspires to someday take his Snake into the big-power zone of 600-plus at the feet. For now, Manny is OK with the impressive 560 rear-wheel horses that his Cobra currently puts down thanks to a Kenne Bell 2.3 supercharger, a CAI, and a free-flowing exhaust.
Manny's fuel-system upgrade...
Manny's fuel-system upgrade is somewhat of a precursor to his plan to step up his Terminator's rear-wheel power output, and a safety measure (ensuring fuel demand is met) for the Cobra's current 560 ponies. As such, a pair of Ford GT supercar fuel pumps (PN PFB-81 4G7Z-9A407-CA; $199) replace the OEM pumps. Fore's plug-and-play fuel-hat wiring is designed with two pairs of 12-gauge conductors, which enable you to wire the fuel pumps directly to one or two fuel-pump driver modules.
However, being OK with that power doesn't mean Manny isn't aware that he is closing in on the limits of his OEM fuel pumps' ability to support it. So, with that in mind, we're dropping a pair of Ford GT fuel pumps in the Cobra's tank, using the aforementioned hat and stock-line adapter.
For time and photo purposes, Mason Rowland of B&D Racing in Van Nuys, California, is spinning the wrenches for us on this project, but the upgrade definitely is one that can be accomplished at home provided you have a means of safely raising your car enough to lower the fuel tank and perform the minor surgery.
Mase secures the factory sending...
Mase secures the factory sending unit to the fuel-hat assembly's stout 1/2-inch spine (the actual hat piece/lid itself also is 1/2-inch thick). The hat is outfitted with 18-gauge wiring through conductors for the sending unit, which are protected by a small piece of shrink tube that is included with the system.
Here is a closeup look at...
Here is a closeup look at the stock-line adapter (PN 0037-022; $55) that really is the heart-and-soul of this conversion. With the Fore fuel hat and this adapter, Manny and his Cobra certainly will benefit from having the bigger fuel pumps (at the car's current horsepower level, and by having capacity, fuel-wise, to step up with a bit more boost) without the expense of converting to the bigger lines and hardware associated with a conversion to return-style fueling.
The Fore fuel hat (left) dwarfs...
The Fore fuel hat (left) dwarfs the factory piece and is designed for optimal fuel delivery, as the factory positive pressure relief valve and restrictive in-tank Y-block are eliminated. The Ford GT pumps we installed are good for 265 lph (as opposed to the Cobra pumps' 255 lph), which will support the 700 rear-wheel horses that Manny expects to have when other changes are made.
The stock fuel line clicks...
The stock fuel line clicks in place, exactly as it does with the original equipment. Teflon sealant ensures that both the adapter and the block-off plug (included) remain leak-free. Once this union is completed, wiring connections to the FPDMs are made and the tank is reinstalled. Note that a quick run on the dyno (to recalibrate the PCM for proper air/fuel ratio) is required after installing the new pumps. This combination is cool because it provides all the features of the Fore Precision fuel hat while allowing use of the stock lines. After tuning, Manny's Cobra responded with a gain of almost 20 hp at the rear wheels and "definitely feels faster," says Manny.
We mentioned earlier that...
We mentioned earlier that Fore's fuel hat is designed to facilitate using two fuel pump driver modules, which is a recommended practice when stepping up to the Ford GT supercar pumps. Lethal Performance developed a wiring harness (PN LP-DUALFPDMKIT; $389) that makes the entire process simple. We added this setup to Manny's Cobra. The extra module is a factory Ford piece (PN XR3Z-9D372-AC) that is included with the Lethal kit, and installing it will enable both fuel pumps to operate fully independent of each other, and reduce overall duty cycle by 30 to 50 percent.