fuel system band aid

stoffer

I paid my buck-o-five
Gen 2 fuel system band aid works for Harley trucks as well

for those of you wondering how to band-aid your fuel system for slightly better than stock power levels well here we go
- disclaimer I am in no way responsible for operator error on your part if you screw something up -


folks have been over running the stock regulator and return line for year after a twin 255 LPH pump install



what you'll need (thanks for the part numbers go to 65fastback2+2 and Modularbigborestroker, special thanks to kspeed for providing the regulator and rails. crewsy for being a role model for me, tbonemcniel for being a good friend also slowpoke31, BossHoss and Capt.EKB for enjoying these threads)







what you'll need:
- Russell Performance Fuel Rail Connector - 640873
- Russell Performance Fuel Hat Connector - 644113
- 10.5'-11' of -6 AN fuel line of your choice (I opted for the PTFE) note: this is length for a regular cab short bed
- two hose ends for the hose you choose to use
- '97-'98 fuel rails
- adjustable fuel pressure regulator (I've used both BBK and Aeromotive without issue the professional products ones I've tried have not lasted nor cleared larger blowers) - the one used here is the aeromotive part 13102
- basic hand tools and fuel fitting tools
- common sense




"pile-o-parts" prior to starting

pile_o_parts_for_larger_return_line_61c3d5d54b5cd7c897d19dd2d9cfc53f2eb6a90b.jpg


prepping_for_larger_return_line_6d42c81a410c0a1456b881eef78d27dd5d3cc695.jpg


local_hydraulic_shop_visit_4c43dbc5eea4b97d71623f42450d1f288e46bcc7.jpg


buying parts



































the hose end fittings mid assembly

ptfe_line_end_install_c6be16361a23d4d97c1c26e234f35da9dadc8b6b.jpg



PTFE end install








going to start with the fuel hat connection ( did the install under the truck and pictures are kinda hard to take in limited space so these will explain a lot as to how the fitting works)



fuel_hat_connection_one_ca76f3f832063c8e3c0eecc2643ce67df104b659.jpg



fuel_hat_connection_two_559bd50e3ae6c891b7b892cfb4281abb9dc6c960.jpg






this is the end ready to go once run up to the engine bay and plugs directly in as the stocker



larger_return_line_setup_for_factory_rails_fc33519da0f7a7ffe503b2bc78639a4f05d31bc0.jpg




plugs directly in


larger_return_line_hooked_to_factory_rails_426d47c7a669aaf0ab486ac6218a08fdd5e88597.jpg



note - I removed the factory return line without cutting or anything and ran the new return line in the same route and clamping points, just a hint, separate at the supplied spot for ease of removal





























also since :stoffer: just a difference in the factory installed regulator and the aftermarket

regulator_comparrison_227efd0c2b981ef0696ee168ba473196031b6f62.jpg





and yes, clears a KB 2.6 or whipple 2.3 with ease

aeromotive_regulator_clearing_kb_90b8fb202bff4924cdb1b11acdb065cf51015f37.jpg
 
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:stoffer : bigtu This thread has helped a lot of folks on the other site
 
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