Homebrew fuel regulator and bypass valves - A

Gary - K7GLD · 02-21-2007, 04:18 PM

In the past discussions related to added pusher pumps, and/or relocated Lift Pumps, it has become evident that while these mods are very helpful in better fuel flow and PSI, they also create a potential fuel blockage issue if they lose power or otherwise fail. That scenario often causes ALL fuel flow to be lost, with a resulting stalled engine due to fuel starvation.

Some of us have built and installed bypass valves and lines around these pumps to allow fuel flow even if the pump has failed - some guys do this with manual ball valves, some. like me, use an automated valve that will change fuel flow automatically, with no manual action needed.

Here's an example of one of mine:

There's been some interest in exactly how these are made, so I decided to make one up out of relatively common ACE hardware store items for guys interested.

Here's a blown-up shot of an easily constructed bypass valve made with ordinary and inexpensive components - a 3/8 in close pipe nipple, 2 3/8 inch brass hose barb fittings, a spring, and a common 1/4 inch or so steel ball bearing:

The barb fitting at the top of that pic looking down inside is to show the seat that the ball bearing seats against when normal fuel flow is present, which closes off fuel flow from the pump output back to it's imput. The spring shown fits loosely inside the pipe nipple, and is only there to prevent the bearing from moving to the opposite end, and closing that end off - the bearing has about 1/2 inch of free travel in this particular design.

Here's that valve in finished and assembled form:

If you apply fuel flow, or simply blow into one end, you get full flow - blowing into the opposite end causes the bearing to seat, and completely blocks flow - all automatically!

(MORE BELOW!)

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

Last edited by Andy : 04-03-2007 at 02:39 AM.

Gary - K7GLD · 02-21-2007, 04:18 PM

NOW, for guys needing a regulator for higher powered pumps like the Walbro with more flow and PSI, here's a homemade valve for that purpose:

In this example, you will see a 1/4 inch stainless steel acorn nut with a 1/4 inch threaded bolt section installed into it - both are then inserted into a commonly available spring selected for this application. On the other side of the 3/8 inch close nipple, you see several 1/4 inch stainless washers - these are shims used to adjust the pressure on the spring, and that of the head of the acorn nut against the surface of the T fitting next to it to the left. This particular setup will provide regulated fuel flow of about 20 PSI - other fuel pressures can be obtained with different springs and/or shims.

If you want to combine BOTH a bypass AND a regulator all in a single assemby, no problem!

The above setup will provide about 20 PSI regulated fuel flow, AND will AUTOMATICALLY open up to allow full fuel flow to bypass the setup if the pump fails!

The finished assembly looks like this:

These setups are easily made - I use JB Weld to seal the various threaded components together, since they require a mix of pipe and compression thread fittings, but that has been no problem, and no leaks to date. These are quick and easy to make, and are very inexpensive - the most elaborate one was about $20 in parts, and is well suited to a Walbro pump - which I just happen to have waiting to be installed on my own truck...

ENJOY!

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

Last edited by Gary - K7GLD : 02-21-2007 at 11:16 PM.

schoust · 02-21-2007, 05:13 PM

Hey thats pretty neat,where was this a few weeks back when I bought my bypas regulater! Where are you getting the springs a balls for this set up?

Dr. Evil · 02-21-2007, 05:33 PM

I like it ! Why cant I be that creative?

Gary - K7GLD · 02-21-2007, 06:08 PM

Quote:

Originally Posted by schoust

Hey thats pretty neat,where was this a few weeks back when I bought my bypas regulater! Where are you getting the springs a balls for this set up?

Most any decent hardware store like ACE or True Value carries a wide variety of springs - I got a whole boxed assortment of springs from them for about $5 - the ball bearings can also be found at some hardware stores, or hobby/craft shops - if all else fails, bug your favorite garage for a an old used bearing race with appropriate sized ball bearings in it, and disassemble it - that's where mine usually come from, and they're usually FREE!

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

grayg · 02-22-2007, 04:20 PM

my plan is to do something on this order, i have a lot of plans it's just the do.
since many are running a pump as a pusher it says running 2 pumps is ok.
i want to remove the stock pump and run 2 holley blues in parallel.
tank line, small header, 2 pumps, maybe filters, check valves, small header, pres relief valve to main line.
thats the rough order of things anyway.
if you loose a pump you still have a pump and you will see a pres drop so you know you have one out.
you will still be able to get in however.
the main idear is having a redundant pump and to be able to complete what you are doing.

__________________
silver/gray 04.5 2500 quad cab 2 whl dr, sony stereo, nv5600/shortened shift arm, 3.73 sure grip, high idle reflash, bed liner and rail caps, tool box, towing packages, ps/mmo or 2 stroke from the beginning.

Gary - K7GLD · 02-23-2007, 03:22 PM

Here's a shot of just the bypass valve installed on a Walbro pump:

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

grayg · 02-23-2007, 05:09 PM

cleand up, that looks marketable, your a smart man.

__________________
silver/gray 04.5 2500 quad cab 2 whl dr, sony stereo, nv5600/shortened shift arm, 3.73 sure grip, high idle reflash, bed liner and rail caps, tool box, towing packages, ps/mmo or 2 stroke from the beginning.

nickleinonen · 03-03-2007, 02:47 PM

creative... i've been trying to make a good low pressure relief valve i can use as a bypass regulator when i get my walbro pump installed on my 04.. i have some nice -8orb check valves, but i can't find proper springs to set the cracking pressure from the >1psi to around 20psi..

__________________
nick leinonen

2004 ram ¾ quad shortie 5.9 ho hand shaker pictures

Last edited by nickleinonen : 03-03-2007 at 02:57 PM.

Gary - K7GLD · 03-03-2007, 05:15 PM

Quote:

Originally Posted by nickleinonen

creative... i've been trying to make a good low pressure relief valve i can use as a bypass regulator when i get my walbro pump installed on my 04.. i have some nice -8orb check valves, but i can't find proper springs to set the cracking pressure from the >1psi to around 20psi..

You'd be surprised what you can find at the local hardware store...

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

nickleinonen · 03-03-2007, 06:46 PM

"hardware" stores don't seem to exist around me anymore

just bigbox homedepot like places.. i've got my eye on a hydraulic relief valve right now. it is adjustable from 70psi - 2000psi, but i think with a trimmed spring, it can come down quite a bit. just waiting for it to go on sale [saw it once for 50%, but didn't get it then

]

Gary - K7GLD · 03-04-2007, 11:55 AM

Our local ACE or True Value usually have enough of the oddball stuff I need for my projects - and I bet a simple Internet search for "springs" would get you more results than you'd have time to wade thru!

OR, even Ebay has them:

eBay: 200 pc Spring Assortment Set Hardware Tools Springs (item 250090222714 end time Mar-05-07 12:25:32 PST)

I swear, some of you young whippersnappers hafta get with this new electronics technology - took me less than 5 minutes to find HUNDREDS of spring sources...:THREAT:

__________________
White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

Last edited by Gary - K7GLD : 03-04-2007 at 12:06 PM.

02-21-2007, 04:18 PM	#1 (permalink)
Gary - K7GLD Tech Specialist Join Date: Nov 2005 Location: Canyon City Oregon Posts: 1,370 Gary - K7GLD's Truck Pics	Homebrew fuel regulator and bypass valves - A In the past discussions related to added pusher pumps, and/or relocated Lift Pumps, it has become evident that while these mods are very helpful in better fuel flow and PSI, they also create a potential fuel blockage issue if they lose power or otherwise fail. That scenario often causes ALL fuel flow to be lost, with a resulting stalled engine due to fuel starvation. Some of us have built and installed bypass valves and lines around these pumps to allow fuel flow even if the pump has failed - some guys do this with manual ball valves, some. like me, use an automated valve that will change fuel flow automatically, with no manual action needed. Here's an example of one of mine: There's been some interest in exactly how these are made, so I decided to make one up out of relatively common ACE hardware store items for guys interested. Here's a blown-up shot of an easily constructed bypass valve made with ordinary and inexpensive components - a 3/8 in close pipe nipple, 2 3/8 inch brass hose barb fittings, a spring, and a common 1/4 inch or so steel ball bearing: The barb fitting at the top of that pic looking down inside is to show the seat that the ball bearing seats against when normal fuel flow is present, which closes off fuel flow from the pump output back to it's imput. The spring shown fits loosely inside the pipe nipple, and is only there to prevent the bearing from moving to the opposite end, and closing that end off - the bearing has about 1/2 inch of free travel in this particular design. Here's that valve in finished and assembled form: If you apply fuel flow, or simply blow into one end, you get full flow - blowing into the opposite end causes the bearing to seat, and completely blocks flow - all automatically! (MORE BELOW!) __________________ White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er. Last edited by Andy : 04-03-2007 at 02:39 AM.

03-03-2007, 06:46 PM	#11 (permalink)
nickleinonen Newbie Join Date: Dec 2005 Location: markham, ontario, canada Posts: 14 nickleinonen's Truck Pics	"hardware" stores don't seem to exist around me anymore just bigbox homedepot like places.. i've got my eye on a hydraulic relief valve right now. it is adjustable from 70psi - 2000psi, but i think with a trimmed spring, it can come down quite a bit. just waiting for it to go on sale [saw it once for 50%, but didn't get it then]

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02-21-2007, 04:18 PM	#2 (permalink)
Gary - K7GLD Tech Specialist Join Date: Nov 2005 Location: Canyon City Oregon Posts: 1,370 Gary - K7GLD's Truck Pics	NOW, for guys needing a regulator for higher powered pumps like the Walbro with more flow and PSI, here's a homemade valve for that purpose: In this example, you will see a 1/4 inch stainless steel acorn nut with a 1/4 inch threaded bolt section installed into it - both are then inserted into a commonly available spring selected for this application. On the other side of the 3/8 inch close nipple, you see several 1/4 inch stainless washers - these are shims used to adjust the pressure on the spring, and that of the head of the acorn nut against the surface of the T fitting next to it to the left. This particular setup will provide regulated fuel flow of about 20 PSI - other fuel pressures can be obtained with different springs and/or shims. If you want to combine BOTH a bypass AND a regulator all in a single assemby, no problem! The above setup will provide about 20 PSI regulated fuel flow, AND will AUTOMATICALLY open up to allow full fuel flow to bypass the setup if the pump fails! The finished assembly looks like this: These setups are easily made - I use JB Weld to seal the various threaded components together, since they require a mix of pipe and compression thread fittings, but that has been no problem, and no leaks to date. These are quick and easy to make, and are very inexpensive - the most elaborate one was about $20 in parts, and is well suited to a Walbro pump - which I just happen to have waiting to be installed on my own truck... ENJOY! __________________ White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er. Last edited by Gary - K7GLD : 02-21-2007 at 11:16 PM.

02-21-2007, 05:13 PM	#3 (permalink)
schoust Cummins Fan Join Date: Aug 2006 Posts: 87 schoust's Truck Pics	Hey thats pretty neat,where was this a few weeks back when I bought my bypas regulater! Where are you getting the springs a balls for this set up?

02-21-2007, 05:33 PM	#4 (permalink)
Dr. Evil Banned Join Date: Jan 2006 Posts: 2,567 Dr. Evil's Truck Pics	I like it ! Why cant I be that creative?

02-22-2007, 04:20 PM	#6 (permalink)
grayg Cummins Enthusiast Join Date: Jul 2006 Location: ar. Posts: 259 grayg's Truck Pics	my plan is to do something on this order, i have a lot of plans it's just the do. since many are running a pump as a pusher it says running 2 pumps is ok. i want to remove the stock pump and run 2 holley blues in parallel. tank line, small header, 2 pumps, maybe filters, check valves, small header, pres relief valve to main line. thats the rough order of things anyway. if you loose a pump you still have a pump and you will see a pres drop so you know you have one out. you will still be able to get in however. the main idear is having a redundant pump and to be able to complete what you are doing. __________________ silver/gray 04.5 2500 quad cab 2 whl dr, sony stereo, nv5600/shortened shift arm, 3.73 sure grip, high idle reflash, bed liner and rail caps, tool box, towing packages, ps/mmo or 2 stroke from the beginning.

02-23-2007, 03:22 PM	#7 (permalink)
Gary - K7GLD Tech Specialist Join Date: Nov 2005 Location: Canyon City Oregon Posts: 1,370 Gary - K7GLD's Truck Pics	Here's a shot of just the bypass valve installed on a Walbro pump: __________________ White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er.

02-23-2007, 05:09 PM	#8 (permalink)
grayg Cummins Enthusiast Join Date: Jul 2006 Location: ar. Posts: 259 grayg's Truck Pics	cleand up, that looks marketable, your a smart man. __________________ silver/gray 04.5 2500 quad cab 2 whl dr, sony stereo, nv5600/shortened shift arm, 3.73 sure grip, high idle reflash, bed liner and rail caps, tool box, towing packages, ps/mmo or 2 stroke from the beginning.

03-03-2007, 02:47 PM	#9 (permalink)
nickleinonen Newbie Join Date: Dec 2005 Location: markham, ontario, canada Posts: 14 nickleinonen's Truck Pics	creative... i've been trying to make a good low pressure relief valve i can use as a bypass regulator when i get my walbro pump installed on my 04.. i have some nice -8orb check valves, but i can't find proper springs to set the cracking pressure from the >1psi to around 20psi.. __________________ nick leinonen 2004 ram ¾ quad shortie 5.9 ho hand shaker pictures Last edited by nickleinonen : 03-03-2007 at 02:57 PM.

03-04-2007, 11:55 AM	#12 (permalink)
Gary - K7GLD Tech Specialist Join Date: Nov 2005 Location: Canyon City Oregon Posts: 1,370 Gary - K7GLD's Truck Pics	Our local ACE or True Value usually have enough of the oddball stuff I need for my projects - and I bet a simple Internet search for "springs" would get you more results than you'd have time to wade thru! OR, even Ebay has them: eBay: 200 pc Spring Assortment Set Hardware Tools Springs (item 250090222714 end time Mar-05-07 12:25:32 PST) I swear, some of you young whippersnappers hafta get with this new electronics technology - took me less than 5 minutes to find HUNDREDS of spring sources...:THREAT: __________________ White '02 Quad cab, NV5600, GAUGES! Comp, Walbro, DTT SS intake, Rip's 4 in. exhaust, Don M's 1.6's, DSS, Frantz oil bypass & fuel filters, Amsoil air filter, MOBILE Ham Radio-IC-706, 600 watt amp, '88 Kit 24 ft. 5er, 418 HP/978 Tq., 24 ft KIT 5er. Last edited by Gary - K7GLD : 03-04-2007 at 12:06 PM.