el-dub801 Member 44 Member For: 12y 9m 17d Gender: Male Location: Wollongong Posted 14/03/17 12:17 PM Share Posted 14/03/17 12:17 PM Guys (and girls?) I had an odd occurance happen to me over the weekend with regards to my fuel system... I recently (finally) got my car going again after replacing a set of keys (thanks Ralph Wiggum) and with that came time to start the car after some time being unused. I replaced my in tank pump with a walbro 255 and the bosch 044 that's attached to a PW surge tank as the fuel had gone sh*tty and didnt want to risk it. I also wired up a relay to the 044 as it hadnt been installed when I had the surge tank installed initially. Typical relay wiring configuration as per recommendations. I cranked the car without the 044 hooked up, then plugged in the fuse for the 044 relay and continued to crank until I heard the pump stop and fuel was primed. This is when I experienced the problem - I heard a loud "POP" and a splashing sound under the car, had a look and found fuel splashing out everywhere! Climbed under and checked all lines and fittings - no issues. No hoses split or missing, but what I did find was a crack down the front side of the surge tank where it was welded. I removed the surge tank and fitted the lines back to original configuration and started the car. No problems. My question is... has fitting a higher flowing pump to the tank unit caused this?? I initially thought that I'd wired the relay incorrectly but since refering to instructions ive found on this forum I realised I could have another issue. I wouldnt think that having the smaller capacity pump feeding the tank and the larger capacity pump feeding the rail would be a problem with hydraulic lock. Can anyone offer any assistance?? Link to comment Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,162 Member For: 16y 9m 15d Gender: Male Location: Melbourne Posted 14/03/17 12:28 PM Share Posted 14/03/17 12:28 PM sounds like a manufacturing fault, to me. Link to comment Share on other sites More sharing options...
el-dub801 Member 44 Member For: 12y 9m 17d Gender: Male Location: Wollongong Posted 14/03/17 12:59 PM Author Share Posted 14/03/17 12:59 PM I guess... for it to split the welds and NOT bust a hose is weird. Although I've been using the same set up for a few years with no issues. I just hope the rest of the welds dont fail once I hook it up again. Link to comment Share on other sites More sharing options...
k31th less WHY; more WOT Site Developer 29,162 Member For: 16y 9m 15d Gender: Male Location: Melbourne Posted 14/03/17 01:01 PM Share Posted 14/03/17 01:01 PM need somebody like @arronm to analyze the metal to figure out where it failed Link to comment Share on other sites More sharing options...
el-dub801 Member 44 Member For: 12y 9m 17d Gender: Male Location: Wollongong Posted 14/03/17 01:08 PM Author Share Posted 14/03/17 01:08 PM If it goes again I'll be fitting a 460lph and I wont be happy - considering what I initially paid for Link to comment Share on other sites More sharing options...
arronm Dropping a turd Gold Donating Members 9,520 Member For: 17y 2m 29d Gender: Male Location: Perth Posted 14/03/17 01:33 PM Share Posted 14/03/17 01:33 PM Did you have all the hoses plumbed correctly when the weld failed. Link to comment Share on other sites More sharing options...
el-dub801 Member 44 Member For: 12y 9m 17d Gender: Male Location: Wollongong Posted 14/03/17 01:38 PM Author Share Posted 14/03/17 01:38 PM Hi arronm Yeah I did. I dug out an installation manual and on PW surge tank, the top two spigots are to and from the fuel tank, the third or bottom spigot is a return from the reg/rail and obviously the supply comes from the poled side of the bosch pump. Link to comment Share on other sites More sharing options...
Ralph Wiggum Moar Powar Babeh Lifetime Members 19,323 Member For: 19y 4m 2d Gender: Male Location: Perth Posted 15/03/17 12:16 AM Share Posted 15/03/17 12:16 AM Get in touch with Kev from process west. I'm sure he'd like to see the tank that failed. If the weld was sound and the tanks had no external impacts/damage there is no way fuel pressure would be able to cause it to fail. Link to comment Share on other sites More sharing options...
el-dub801 Member 44 Member For: 12y 9m 17d Gender: Male Location: Wollongong Posted 15/03/17 12:36 AM Author Share Posted 15/03/17 12:36 AM I spoke to Kev over the weekend but I didnt mention the break. I just wanted to clarify the 100% that it was plumbed correctly. Ive had it welded up already and ill hook it up again this weekend. Fingers crossed that its ok. Link to comment Share on other sites More sharing options...
Ale Member 249 Member For: 13y 5m Posted 15/03/17 12:51 AM Share Posted 15/03/17 12:51 AM amazing , and all this time I figured all this high end, expensive locally made stuff was the ducks guts, imagine if this had been a Pro Flow surge that failed, thread would be 10 pages long. Link to comment Share on other sites More sharing options...
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