Twin Bosch 044 Fuel Pumps Plumbing

Hey up Justin. How are you?

Thanks for the input. As usual you hit one important the nail on the head.

I am looking to fabricate all of the brackets for aluminum sheet, a good vibration absorber, using the original rubber inserts from the EV set-up, and bolt it up to the original under-body mounting studs. I'll also use the large diameter Kit Car rubber bobbins to mount the pump brackets to the main under-floor bracket. Then, I'll wrap the pump body with dense foam sleeve when I clamp them up. I'll use spare bits from the foam sheet that VW supply for damp proofing behind the door cards for this. That should isolate everything I hope!?

My filter will be mounted at the K-Jet metering head as with the VWMS Mk2s. So there won't be any loads outside the pump axis to cause eccentric forces.

 

some of the rally quatrros ran 3 fuel pumps gravity fed from a swirl pot in the boot, im sure some of them were push fit with jubilee type clamps, on a steel TTT piece (you get the idea)

i have some pictures ill see if i can find them. similar to this one, althought this is a later on with expensive fittings!

 

OK folks.

I have found a supplier for the braze fittings in both 12mm and 16mm single and double.

Now. I shall be forced to buy a quantity, probably 10 off each minium, and the price is not yet known. I also need to buy more silver soder rods and more flux.

I did not really want to get into making lots of parts again, as the bronze bushes I made, caused me too many problems.

But, if 9 other people do show an interest, I will consider the investment as I really want to make a set for my own use.

I will work out prices as soon as the supplier give me the details.

Dave.

 

3mm Duralumin - 53gms - 4 (incl: etch primer and satin black finish)



















The pump with a push on end is from an Audi Quattro. The short length of 50mm pipe with a flanged end, is for making one of the exhaust stubs, from the manifold flange, to fit a spring retained 60mm exhaust system,



IF ANYONE HAS SPARE ELECTRICAL CONNECTORS, SEALS, SLEEVES, ETC., AS BELOW, PLUS THE SHORT WIRING LOOM THAT GOES WITH IT, I WILL BUY THEM FOR THE SECOND PUMP!





About 10 hours work: designing, drawing, making the jig and making the bracket.

At 50/hour for a uber skilled alloy worker = 500 eachlol

 

Nice job. Nice to make stuff!

 

I`m lazy and use ... https://www.merlinmotorsport.co.uk/p/sytec-fuel-pump-filter-bracket-mpb00

 

I am in!

2 sets possibly pending on price and will ask around if anyone else wants some

 

Yes indeed, on home ground.

Will visit next month for sure, arc is fine for me for the thickness in hand - when they start using mig on nuclear piping Ill make the change, but not until then.

Keep the chin up Dave, every day is another different one,

Brian,

 

Thanks Rob.

You should know me well enough by now Andrew to realise that 'Bright Blue Bling' is definitely not my style!

Plus. The orientation of the mountings, across the pump axis, is, IMHO, wrong!

I have found another possible supplier for smaller quantities and will persue that.

 

I have been involved with quite a few nuclear engineering designs for both Sellafield and Sizewell. In fact some of the machines in Sizewell 'B' rector building are my design! Now, there was some mig welding in those machines!

Brian. To make the trip worthwhile we need some 40mm OD x 30mm ID hollow bar if you have any lying around? About 400mm should do the job!lol

 

Yes Dave, but they were only the ladders and cat walks needed by the arc welders to gain access for the pipe jobs

I will call this month sometime, dont worry.

Brian,

 

I managed to find a couple of hours to knock these up!
The large banjos are 16mm opened out to 18mm. They were fittings with tails which I removed and bored out to 12mm.
The small fittings are standard 12mm tailed fittings. I cut off the tails again and reduces the ends to 9.5 mm. Standard 12mm fittings are only 6.5mm bore so I opened them out to 7.5mm to match up with the bore oe the JIC#6 end conectors.
The tube is made from an 020 gear change lever. I opened it out to 7.5mm and, for the 12mm banjos, bored the ends to 9.7mm.
All silvered soldered.
The rubber mounts are Audi, as is the 18mm banjo. (90 20V Q Power Steering)

 

Pls pm me the price for the kit as i am still interested

 

Sam.

I am sorry but I can't really consider making a set for you. I wish I could help you out but I don't have machine tools to do the job properly!

Below are photos of how I did the job. I cut and turned the banjos using a bench grinder, a chuck and a file. I drilled and bored using a simple drill press.

I had some difficulty getting good results and spoiled one or two parts. It took many hours!





I had to make jig to ensure the banjos were parallel and level.



Regards,

Dave

 

SAM!

Get hold of a 'Race Parts' catalogue. On page 57 is a machined billet twin pump plumbing kit comprising: manifolds, bracket and fittings. The price in the catalogue is 145 + vat.

It is not on their web site?

Regards,

Dave.

 

Recalling Dave`s work ... came across this whilst looking for Escort parts

 

We're using that exact item on our BMW project..

 

I would be careful to mount this type of design across the chassis.

The rubber mounts are quite close together across the axis and the pumps are heavy, as is a filter full of fuel.

The main forces acting on the system are due to acceleration and braking.
Across the car will rock the system less than along the car.