Templates for Regulated Return

August 30, 2014 · by · in , , , ,

For my regulated return fuel system, I need stainless fuel lines in the engine compartment:
– supply line 1/2″ to a distribution block
– 3/8 line from distribution block to passenger side head, rear
– 3/8 line from distribution block to driver side head, rear
– 3/8 line from pressure regulator to passenger side head, front
– 3/8 line from pressure regulator to driver side head, front
– 3/8 line from pressure regulator to fuel return

The approach I decided on is as this:
1. Partially disassemble the top of the engine, including the intake tubing to gain access to the “valley” of the engine, the currently used fuel supply fittings in both heads and fuel rail plugs in both heads.
2. form the lines in copper (easier forming) to have the 3D shapes, account for adjust-ability, deviation from the “perfect” shape, vibrations and heat expansion.
3. re-assemble the top of the engine.
3. form the stainless tubing to the copper tubing, purchase the required fittings, fabricate the distribution block, and a mounting adapter for the pressure regulator.
4. mount in truck.

This weekend, I formed the copper lines.