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  • 1996 - 2004 SN95 Mustang -General/Talk-
  • SN95 4.6L Mustang Tech

Returnless Fuel To Return Syle Conversion

  • Thread starter Thread starter bhuff30
  • Start date Start date Nov 13, 2013

bhuff30

Founding Member
Dec 11, 2001
6,037
35
129
Olathe KS
Nov 13, 2013
#1
  • Nov 13, 2013
  • #1
I am working on a build right now and have a stock 99-04 fuel tank with pump, pickup, level sensor and everything I need. However, the build is going to use a return type of fuel system, so I need to add a return port to the 04 fuel tank. Does anyone have suggestions for how I can add a return port to that tank?
I would prefer not to weld one on myself. I only have access to an old arc welder and would more likely burn a hole in a perfectly good tank/hat.
Does the 99-04 V6 use a return style fuel system? If so, I could grab a hat from a 99-04 V6 and bolt it on?
Will a hat from a 96-98 mustang bolt on to my 99-04 tank?

I saw that lethal performance sells a hat with a return, but at $400+, I would be better off financially buying a new 87-98 tank and components.

The application is for around 400hp, so I don't need a huge amount of fuel flow. Probably just a walbro 255.
 

tank_567

Active Member
Mar 19, 2007
731
26
29
Raleigh, Nc
Nov 13, 2013
#2
  • Nov 13, 2013
  • #2
bhuff30 said:
I am working on a build right now and have a stock 99-04 fuel tank with pump, pickup, level sensor and everything I need. However, the build is going to use a return type of fuel system, so I need to add a return port to the 04 fuel tank. Does anyone have suggestions for how I can add a return port to that tank?
I would prefer not to weld one on myself. I only have access to an old arc welder and would more likely burn a hole in a perfectly good tank/hat.
Does the 99-04 V6 use a return style fuel system? If so, I could grab a hat from a 99-04 V6 and bolt it on?
Will a hat from a 96-98 mustang bolt on to my 99-04 tank?

I saw that lethal performance sells a hat with a return, but at $400+, I would be better off financially buying a new 87-98 tank and components.

The application is for around 400hp, so I don't need a huge amount of fuel flow. Probably just a walbro 255.
Click to expand...

I can ask my brother if he can do it for you, I'll PM you later.

 

bhuff30

Founding Member
Dec 11, 2001
6,037
35
129
Olathe KS
Nov 13, 2013
#3
  • Nov 13, 2013
  • #3
Your setup looks perfect. I assume that is an AN fitting, from which I could adapt to whatever I need? Let me know what your brother says, I would be happy to do business.

I was reading that some people have installed a bulkhead connector. That would work, but I still see the opportunity for leaks since it isn't welded.
 

flstang65

10 Year Member
Dec 6, 2007
1,484
135
94
SE Georgia
Nov 13, 2013
#4
  • Nov 13, 2013
  • #4
Would this work? You would need an external fuel pump though.
http://www.uprproducts.com/mustang-fuel-tank-pickup-tube.html

On a side note, saw these. They looked pretty cool.
http://www.uprproducts.com/mustang-billet-fuel-rail-adapters.html
 

bhuff30

Founding Member
Dec 11, 2001
6,037
35
129
Olathe KS
Nov 13, 2013
#5
  • Nov 13, 2013
  • #5
flstang65: looks like that hat would work fine for running an external pump. I'll keep that in mind incase I don't see any other options. I was kinda hoping to stick with the internal pump just because I am familiar with it and I know it works.
 
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