The car uses an OEM Suzuki GSX-R1000 fuel pump mounted in an external swirl pot. The swirl pot is fed by another electric fuel pump that draws from the fuel cell, with excess fuel returned to the fuel cell. The swirl pot will generally be full, providing a buffer in case the pickup in the fuel cell temporarily sucks air during hard cornering or braking. The shape of the swirl pot is tall and narrow, with the fuel drawn from the bottom so that the engine should never experience fuel starvation.
The swirl pot was fabricated from 1/4″ thick aluminum plate and tube stock just big enough to fit the OEM fuel pump inside. Welding was done by an outside professional welder. An interesting fact about the Suzuki fuel pump, discovered a bit late, is that the five bolts appear to be evenly spaced but aren’t. One of them is off by a bit, probably so the pump can only be installed in a single orientation. This necessitated welding one of the holes closed and re-drilling it.
The OEM fuel pump has a large appendage for fuel level sensing which clearly won’t fit into a small swirl pot, so I cut it off. it would be nice to have a level sensor in the swirl pot so I can watch fuel starvation and get enough warning to get back to the pits before I run out of fuel, but I haven’t figured a way to do this yet.
Fuel pump before trimming
Level sensor bracket was cut like this
Fuel pump with level sensor removed
View of disassembled swirl pot components before welding
Swirl pot lower flange, showing O-ring groove
Test fitting swirl pot components
Finished swirl pot with OEM fuel pump installed, lower view
Starting the blank for swirl pot mount
Building braided stainless steel fuel hoses with AN fittings.
Drilling the firewall for fuel lines
Fuel lines from firewall to fuel cell. Bottom line goes to first fuel pump; top line comes back from swirl pot overflow.
Fuel hoses come through engine side of firewall
Low-pressure fuel pump sucks fuel from the fuel cell through a filter to the swirl pot
Swirl pot supply and return lines
Fuel supply to engine exits from the bottom of the OEM fuel pump.
OK, time to get caught up on blog posts. Experience the agony of defeat and the joy of victory along with me as I debug the electrical system one fault at a time, prepare the engine for starting, and debug the engine. GSX-R1000 engines have a sensor that looks for the original ignition switch, and won’t start without it. This had to be worked around, followed by a determination that all the fuel injectors were clogged. I then made a device to clean and test the fuel injectors…
Click the photo to watch the video on Youtube.
Ready to fill the engine with oil, coolant, and gasoline.