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 »  Home  »  2nd Gen 24V Articles  »  Performance Upgrades  »  Vulcan Draw Straw Installation
Vulcan Draw Straw Installation
By piper ca | Published  04/3/2007 | Performance Upgrades | Rating:
Vulcan Draw Straw Installation
Since the new Vulcan Draw Straw has been getting a lot of attention recently, I put together a “how to” article to help some of the guys, who are still on the fence, make the decision to “git ‘r done!” The install is much easier than most would think, only requiring basic skills and tools to complete the task … so here goes!

I took quite a few photographs during my install, which will hopefully assist in explaining how easy the install is. Unfortunately, I didn’t take photographs of the tank removal/reinstall, but it’s not rocket science.

Start by dropping the tank from the truck. A very easy process, which requires disconnecting the tank fill and vent tubes, the fuel feed and return lines from the module and the electrical connector from the module. From underneath the truck, loosen the two nuts, which hold the retaining straps in place, until a few threads remain. Using a jack, support the tank, then remove the two nuts and the straps, completely, and lower the tank with the jack.

Some prefer to remove the bed of the truck to get access, but that’s going to be up to you. I think the tank removal method is pretty straight forward.

Once the tank is out of the truck, and located where you can work on it, use a block of wood and hammer to remove the retaining ring from the module. Place the block of wood against the ribs of the retaining ring and gently tap (counter-clockwise) with a hammer until the ring loosens.

Remove the module from the tank, being careful not to spill the fuel that has collected inside the module. Pour the fuel back into the tank or you may siphon any remaining fuel into containers to make the install cleaner.

Using a pair of dikes (snips), cut the main pickup tube via the opening in the side of the module.

Remove the pickup/return fitting by prying the fitting out of the rubber grommet. Be careful not to damage the grommet, as it is reused in the install.

Separate the two halves of the module, being careful not to damage the fuel level sensor and wires. Remove the pickup tube from the lower half of the module.

Remove the strainer basket from the base of the module and cut the inside screen away. You may also remove the outer screen or discard the strainer basket altogether, if you want.

Using a step bit, ream open the hole in the base of the module to approximately 5/8” or to a size adequate to accommodate the pickup tube. You may drill a couple of ” holes next to the pickup hole to assist in allowing the fuel inside the module to drain. I chose to drill the pickup hole slightly larger than the pickup tube to allow the fuel to drain around the tube.

Reassemble the module and install the Draw Straw using the original rubber grommet. The pickup tube will protrude through the hole you enlarged in the base of the module.

Time to measure! Using a straight edge (level, etc.), lay the straight edge across the mouth of the tank opening then measure from the base of the tank to the underside of the straight edge. Check a couple of times but cut once! Record the measurement.

Lay the module on its side and measure from the underside of the rubber grommet around the module to the desired length on the pickup tube … double check this measurement before cutting! If you are going to reinstall the strainer basket, you’ll have to remove an additional 3/8” off the end of the pickup tube. If not, cut the tube to the desired length, cutting at an angle to alleviate any problems with the bottom of the tank. I cut my pickup straight across then cut four scoops/scallops around the pickup to allow for sucking fuel.

If you have discarded the strainer basket, you may want to fix the two halves of the module together, so they don’t move and affect the fuel level sensor. The measurement for this should be done taking into consideration that the strainer basket rested on the base of the tank. Use a couple of self-tapping screws to accomplish this.

Replace the module into the tank and, using the block of wood and hammer, tighten the retaining ring. Be careful not to over tighten the retaining ring.

Attach the fuel lines to the Draw Straw before mounting the tank in the vehicle.

Reinstall the tank using a jack to support it. Reinstall the front retaining strap on the front of the tank, but leave it loose. Swing the rear of the tank away from the frame rail. Cut and attach the return line to the existing metal fuel line. Reinstall the rear retaining strap and fully secure both front and back straps.

Reinstall the fuel tank fill and vent hoses, electrical connector on the module and route the fuel feed line from the Draw Straw to your fuel pump, which is hopefully mounted on the frame rail.

When I did the install, I installed the AFS Big Dog Fuel System, so it was a pretty clean install from VP44 to the tank.

Believe it or not, that's all that's to it! A very simple install, if you take your time, and awesome results!

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