DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank - Team Camaro Tech
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post #1 of 28 (permalink) Old Jan 23rd, 17, 10:13 AM Thread Starter
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Ryan
 
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DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Before anyone attempts this, please note that neither myself or this site is responsible. Working with flammable fuel is dangerous. Please attempt at your own risk

That said, my dilemma was that I wanted to find an alternative to the LS swap tanks that I have seen that have been all over the map, with some well over the $1k mark. I wanted similar performance, but I didn't want to pay that price or sacrifice the performance of my tank. After reading all of the difficulties that people were having with the Spectra tanks, I decided to do some research. After some searching, I came across the stamped tank from Rick's and that was very similar to what I wanted and utilized the stock 5th gen Camaro fuel pump assembly. The problem is the tank was $400 (much cheaper but still too much for me), and I would have to buy the fuel pump, PWM and sending unit.

I posted a question on this site a while ago with a question about the 5th gen pumps, and Carl from Vaporworx replied back that they had developed the parts to convert the 5th gen fuel pump assemblies over to run a constant 58psi. That was just what I wanted, a stock fuel pump assembly for ease of use and designed for longevity, but didn't need an expensive module to run. I used a 4th gen fuel pump assembly on my 1976 Trans Am when I did the conversion and it worked flawlessly. I wanted that sort of reliability.

Help putting 5th Gen Camaro Fuel pump in 68 Camaro Tank - LS1TECH

With that information, I came to the conclusion that I was going to modify my fuel tank to accept the 5th gen fuel pump assembly as it fit the bill with exactly what I was looking for. I needed to have something that was short enough to fit into a recessed panel in the stock tank, supply enough fuel to my motor without starvation, and have the correct fuel pressure to run an LSx motor. According to Carl, after this mod the fuel pump will supply the equivalent of a Walbro 255 pump. WIN

The next decision I had to make was how to attach the fuel pump assembly to my fuel tank recess. I used the Vetteworks adapter when I did my LS1 swap in the 76 that worked incredibly well, but still wanted something more stock appearing. After more research, I found that the Chevy Colorado's use the same size fuel pump assembly opening, so I could attach that to my fuel tank recess, and use the stock clamping ring. Now, my plan is complete and I need to start collecting parts.

Here is what I am started with. It is a 2011 SS Camaro Fuel pump assembly from a 53k mile car. I scored this on ebay for $59 bucks free shipping from a salvage yard!



With a little research and looking around, I found a local pick and pull yard that had a '09 Colorado. After a quick trip to the pick-a-part, my sawzall make quick work to get this little guy out!



After sketching out some dimensions and seeing what would work with this pump and the mounting ring, I had my game plan.



I wanted to get the mounting ring as round as I could, so with some "creative engineering", I was able to come up with this method. I was using the inner circle as my template, and fixed my grinder into position. It worked great!





Next up was getting the gasket surface as flat as I could. After giving this some more thought, I decided to use a similar method. I used my phone's level, and got the grinder perfectly level both side to side and front to back. I mounted it in place, and slowly worked the surface. Since I am going to use a Viton(r) gasket, it should take up some of the imperfections that this surface has. Overall, I was very pleased with the results from my makeshift methods... or whatever you want to call it.







And the final result for my fuel pump adapter ring.





For the final installation, it will have a Viton(R) gasket sealed up between it and the recessed panel I will be putting on my fuel tank. I will make a ring that will fit inside the tank that will bolt everything down.
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Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #2 of 28 (permalink) Old Jan 23rd, 17, 10:13 AM Thread Starter
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Ryan
 
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

I first started, by taking all of my measurements for the adapter ring that I made from a '09 Colorado fuel tank, and where it would sit in relation to the fuel tank recess I want to make. With the fuel pump assembly attached to the adapter ring, the height I wanted was 6.25" tall. That gave me the measurements I needed to start my template. I cut mine out of some thin cardboard I have been saving for this project.





Once I had the template, I measured where it would fall in relation to the fuel tank. I wanted it centered, and where the outlet of the fuel pump assembly would be pointing in the right direction. My template measured 10" x 10", and will recess the pump roughly 1.25". No turning back now! I opted to use metal sheers rather than a cut off wheel for two reasons; one is it will greatly reduce the debris and two that it will not produce sparks like a grinder would.





Luckily it fit right in between the two ribs on the tank.





And test fit, it is going to work perfectly. I wanted the compressed height of the assembly to be between 6.25" and 6.5" and it measured in right at 6.5" with my template. Perfect. Now for those wondering, the fully compressed height for the assembly is 5.75" and the fully extended height is 7.125". So somewhere in the middle is right where I want to be.



Now, my original plan was to cut my recess out of stainless steel, but due to the added complications, I just used mild steel. I had a piece of 16 gauge steel, which is a little more rigid and won't give any issues with welding to the tank.



To make the bends much cleaner, I used a tape line and my cut off disk on my 4 1/2 grinder and cut a small line where I wanted the bends. I saw this trick somewhere else online, and it worked incredibly well. The lines are so clean and the bends are spot on.





And here is the first trial fitment.


Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #3 of 28 (permalink) Old Jan 23rd, 17, 10:14 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

I printed off a seven piece pie chart on the internet to use as a template, and drilled my holes in the adapter ring. I then transferred those holes to my recess panel. I put the recess panel in the tank and did a trial run in the car. After the first fitment, it was clear that the panel needed to go down about an inch to clear everything. I also made sure to clock the fuel pump pick-up to ensure that it will be submerged enough.





I cut the tank just a little more, and now the pump sits just slightly lower than the top of the tank.



I used my square and made sure that it was perfect on both sides. I got the welder dialed in and this is how it turned out. Very smooth and excellent weld penetration.





Welded some nuts to the bottom side.



I made sure that everything was level and then tack welded in a few spots. One final test fit before I burned it in for good.



After I started working on everything I decided that I was going to butt weld the panel. After a few inches of weld, it was turning out better than I had expected. Then before I knew it I was done welding.







After a little love with the flap disk.





After primer and paint.




Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #4 of 28 (permalink) Old Jan 23rd, 17, 10:14 AM Thread Starter
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Ryan
 
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

I needed to address drilling the holes for my fuel tank sending unit. I used the gasket for a template and drilled them out. After that, I filed any burrs and got to work with the inside of the tank. I used about 12 brand new shop rags, brake clean, and a magnet, but it cleaned up really nicely. I kept using the new rags to monitor how dirty they were when I was done wiping the tank. Once I saw satisfied, I re-installed my adapter ring for good with my Viton seal. (bought a 9" remnant from ebay and made my own gasket) The fuel sending unit is a universal sending unit that can be had on eBay or Amazon that reads 0-90 Ohm.

Once the fuel sending unit was in for good, I had to bend the level sender float so that it would read empty and full while still clearing the recess panel. It took me a little bit to figure out the angles, but it turned out pretty good and I am satisfied that it will read correctly. Having a 5" hole in the top of the tank helps with making those small adjustments too.



All buttoned up and installed for a final time.



Now was the part that I was excited to start; modifying the stock fuel pump assembly to run at constant 58psi. I kit is from Carl at Vaporworx, and I have been patiently waiting for the tank to be done before I did anything with the pump. I used a little cleaner and a scrub brush to clean up the pump assembly and it looks brand new!



I followed along with the highly detailed instructions that were provided, and it was incredibly easy. First step was to remove the retaining ring and remove the stock fuel pressure reg.





Once it is removed you end up with this. There is also the grounding ring that needs to be temporarily moved to the side.



This is the heart of the conversion. This is an adapter that was developed by Vaporworx and is what allows for the new fuel pressure regulator to work properly.





Like it mentioned in the instructions, the filter was in the way for the adapter to seat properly, so I had to gently move it to the side. I ended up installing it at an angle, and it worked like a charm. Hard to get a picture, but there is the filter in the way.



Adapter fully seated



Here is a comparison of the 4th gen fuel reg vs. the stock one that came out. 4th gen on the left and stock on the right.



And fully installed. Don't forget to re-install the grounding ring.

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Fully completed swap. Here are all of the tools that were required for the job too.



(this tag is for future reference)



And here is the fully installed tank. I threw some paint on the stock retaining ring, but will get a new one before final install in the car. For now it works fine to hold it down to keep debris out.





Ready to go into the car! The only modification I may make is to bend up a hard line from the pump assembly to the driver's side front of the tank for a cleaner install.



For those wondering how I did from a cost perspective, I am listing it below:

LS3 Camaro fuel Pump $59.00
Colorado Mount w/ Ring $2.00
Recessed Tank Panel Metal $30.00 (even though I already had it)
Parts from VaporWorx $101.99
0-90 OHM Sending Unit $5.00
Viton Gasket $8.96

That is a grand total of $206.95

Still need to wait to see how it performs, but I have no doubts that it will live up to my expectations. I feel that is a much more reliable option than the Spectra tank, despite the work to complete.

Thanks,
Ryan

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #5 of 28 (permalink) Old Jan 23rd, 17, 10:15 AM Thread Starter
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Ryan
 
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

I will keep this reserved for my impressions once installed in the car. Carl said that people that have installed his kit in the 5th gen pumps have reported no fuel starvation with as little as 1 gallon of fuel in the tank. Time will tell.

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #6 of 28 (permalink) Old Jan 23rd, 17, 11:12 AM
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Nice write up. Seems like I recall reading or being told these set ups don't require any baffling. That maybe on the ones that run pick ups in both corners.

I wish this pump would support the fuel requirement I'm needing. I'll be running a dual Walbro 450 set up. But I definitely like what you've done.

My Mistress rebuild...
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Last edited by zboss86; Jan 23rd, 17 at 11:18 AM. Reason: Found the answer for PWM in the first paragraph.
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post #7 of 28 (permalink) Old Jan 23rd, 17, 11:15 AM
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Maybe I missed it but are you running the corner pickups? I think they are needed to meet Carl's one gallon claim.

Don

1969 Camaro LSA 6L90E AME subframe and IRS
1969 Camaro vert LS3 4L65E Ridetech level 2 - sold
1959 El Camino project
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post #8 of 28 (permalink) Old Jan 23rd, 17, 11:16 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Thanks, I posted this on here too as it seems this site is more geared towards first gens. With the 5th gen module there is no return line. The modification that I did using the 4th gen fuel pressure regulator will purge the fuel back into the fuel bucket which eliminates the PWM. And yes, because of that the returned fuel always keep the bucket full so no baffling is required. Vaporworx has tested this with less than 1 gallon of fuel in a pro-touring car without any starvation issues.

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #9 of 28 (permalink) Old Jan 23rd, 17, 11:17 AM
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Quote:
Originally Posted by zboss86 View Post
Nice write up. Seems like I recall reading or being told these set ups don't require any baffling. That maybe on the ones that run pick ups in both corners.
Never mind...

Don

1969 Camaro LSA 6L90E AME subframe and IRS
1969 Camaro vert LS3 4L65E Ridetech level 2 - sold
1959 El Camino project
1969 Mustang Sportsroof project
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post #10 of 28 (permalink) Old Jan 23rd, 17, 11:18 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Another nice thing about this modification is that the CTS-V uses the same fuel hat so it is a direct bolt in. Then I can use the PWM and the CTS-V when I go with a turbo. But for now the stock 5th gen pump will work great for N/A

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #11 of 28 (permalink) Old Jan 23rd, 17, 11:22 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Quote:
Originally Posted by zboss86 View Post
Nice write up. Seems like I recall reading or being told these set ups don't require any baffling. That maybe on the ones that run pick ups in both corners.

I wish this pump would support the fuel requirement I'm needing. I'll be running a dual Walbro 450 set up. But I definitely like what you've done.
No, I opted to run the pump without the corner pick-ups. After talking with Vaporworx, they said for my street car they weren't necessary. As for the fuel requirements, any pump that will fit a 5th gen will fit my tank.

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #12 of 28 (permalink) Old Jan 23rd, 17, 11:32 AM
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Quote:
Originally Posted by ryeguy2006a View Post
Thanks, I posted this on here too as it seems this site is more geared towards first gens. With the 5th gen module there is no return line. The modification that I did using the 4th gen fuel pressure regulator will purge the fuel back into the fuel bucket which eliminates the PWM. And yes, because of that the returned fuel always keep the bucket full so no baffling is required. Vaporworx has tested this with less than 1 gallon of fuel in a pro-touring car without any starvation issues.
Interesting... I was wondering what kept it from having fuel starvation. The rep just told me it was due to the dual pick ups, but I couldn't make sense of that. Seems like the 2nd pick up that was not in the fuel would be sucking air. But I'm probably missing something.


Quote:
Originally Posted by ryeguy2006a View Post
Another nice thing about this modification is that the CTS-V uses the same fuel hat so it is a direct bolt in. Then I can use the PWM and the CTS-V when I go with a turbo. But for now the stock 5th gen pump will work great for N/A
Do you know what power range the CTS-V pump is good for?

My Mistress rebuild...
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post #13 of 28 (permalink) Old Jan 23rd, 17, 11:35 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Zboss, the corner pick-ups function in a way where they have a check valve or something similar that will prevent exactly what you brought up. It will shut off if it isn't submerged.

Not sure the range of the CTS-V, but I know that people make big power with them. Good question for Carl from Vaporworx if he is on this site. He is a wealth of knowledge.

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #14 of 28 (permalink) Old Jan 23rd, 17, 11:36 AM Thread Starter
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

He told me that the the stock 5th gen pump is the equivalent of a Walbro 255, which was good for the 42lb injectors on the LS3.

Project: 1968 Camaro 5.3, T56, Z51 brakes, 12 bolt, etc.


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post #15 of 28 (permalink) Old Jan 23rd, 17, 11:44 AM
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Re: DIY 5th Gen Fuel Pump Assembly in stock 1968 Camaro Tank

Quote:
Originally Posted by ryeguy2006a View Post
Zboss, the corner pick-ups function in a way where they have a check valve or something similar that will prevent exactly what you brought up. It will shut off if it isn't submerged.



Not sure the range of the CTS-V, but I know that people make big power with them. Good question for Carl from Vaporworx if he is on this site. He is a wealth of knowledge.
the check valve idea makes sense...

I'll look into that style pump, I've never really considered going that route b/c of the cost of those set ups. But what you did is an inexpensive option...

My Mistress rebuild...
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