Prototype Surge Tank

June 29, 2017

Our cars are getting faster, we run more boost and every year it seems like the bar is raised… 400hp used to be fun, 500hp was amazing and 600hp+ was crazy. Nowadays if it’s not 800, 1000 or 1200hp, it doesn’t get much of a mention. Well that’s competitive race cars, we still see a lot of 300-600hp street cars coming through our shop and one thing is common with all of them…. The majority of the time the fuel systems sit on the edge of disaster.

It’s so common to see a single Walbro 450lph fuel pump jammed into a stock tank and the car running enough boost to melt engines in the event of a fuel surge or pressure drop. As prices of big power items get cheaper (turbos, injectors, fuel pumps, etc, etc) we have found a lot of our customers’ overlook the importance of a good fuel delivery system. Yes there are many brands out there with great surge tank kits but a lot of people aren’t willing to spend the $700-$1200 for a surge tank, let alone another few pumps!

Now there are some well priced, reasonably good surge tanks for Bosch external pumps but we haven’t come across anything that will let us drop in a few 450lph internal pumps. With that in mind, we’ve decided to fill that void with our prototype surge tank kit. We’ve found a suitable pre-fabricated tank that will house either 1 or 2 pumps depending on your fuel requirements (and budget).

The tanks feature three -6AN ports for fuel tank feed, fuel tank return and fuel rail return. We’re in the process of designing and manufacturing the pump cradles which will also feature the -6AN fuel outlet and some insulated electrical posts for wiring the pumps correctly. We’ve seen the Walbro 450’s draw more power than OEM fuel pump cradles can handle so we’re making sure everything in our kit will support the power and current draw of these pumps at very high pressures.

We are starting off with 3D printing the cradle and hanger, this allows us to make sure every component will fit and function correctly. We’ve already gone through a few different designs and we’ve ended up with something we believe will be cost effective and robust. From the design and 3D printing stage, we will be moving onto machining the required parts from aluminium. We’re going to do this in house using our newly acquired CNC router.

Stay tuned for our next post once we’re up and running with the router. Once machining is complete, we’ll be putting our tank through some pressure tests then onto a few of our own cars before we put them to market.