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Deatschwerks X3 Fuel system

Angrey

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I wrote about this in other threads. When I started my fuel system journey several years ago, I found one system on the market that was 1000 rwhp capable, drop in the factory tank, brushless and variable control. Simple, rock solid. Unfortunately, it was Fuelab's setup for the S197 cars and they had discontinued it. No one bought it. They were essentially 10 years too early to the market. They put a lot of time and R&D into fitment and fab and virtually no one bought it.

I spoke with virtually ALL the major players in the market at that time. Fuelab, Radium, Deatschwerks, Aeromotive, Fore.

Fuelab wasn't interested because they'd already been burned so to speak. Aeromotive wasn't interested because they do fuel systems across multiple vehicle platforms. The engineer I spoke with at the time even indicated that because the newer mustangs were IRS/Saddle tank (like the corvettes) they weren't interested in a factory fuel cell solution. And anyone wanting that level could go with an after market fuel cell or surge tank.

And there was a ton of gravity and resistance to moving away from the tried and true, triple pumps running full boogie or staged on a return line.

And although the number of cars running around at 1000 rwhp has increased dramatically, you have keep in perspective it's still a very small consumer pool. Meaning if there's now 10,000 or even 50,000 cars running around with those needs, it's still a very small market compared to the consumer market for the established products.

At one point, I even considered starting my own business. But when I started to dive deeper into it, I realized kinda their point. I'd put a whole bunch of money into it with muted potential on the back end. The only way it makes sense is if a performance shop/vendor who's building or fabricating a system for their own cars/needs wants to replicate it and sell it as a kit. Which is what we've seen.

Eventually a bunch of them came around and started offering at least more bits and components of a brushless, variable, in OE tank set up.

I do think however, we're still a little at the "you can have it effective, you can have it economical, you can have it simple, now pick any two" scenarios.

I chose the effective, expensive and complicated route. I think today, the prices on my setup have come down (even against the tide of inflation) because there's just more stuff to select from. But I chose the complexity because I wasn't keen on compromising on just about anything.

And some of the performance aspects are admittedly "obscure." Do I really need to be able to mash when the fuel level is very low? For me, the answer is yes. When I'm cruising on a long drive, I don't want a "window" of when it's safe to smash and then have to either make a risky choice or just forgo romping it when the fuel gets lower. A LOT of the market just chalks it up to "race car" and gives up on that aspect.

Ideally we could at LEAST buy pre fabricated system components. Like a shop that sells just the feed and return lines, fittings, filter, regulator, all already assembled and basically "plug and play" and then from there you could buy the other system elements like the pumps and housing, controls, boosters and wiring, etc. About 50% of the complexity for me was the lines and fittings.

If I were to do it over again, I'd probably go with a BKS pump in a Radium bucket with a fuelab electronic regulator, repurpose the factory feed as a return line and install a new feed line. That would get to around 800 or 900 rwhp reliably on E85, and with a booster of your choice, well out into the 1200-1300 hp range.
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Cordero1

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I am certain this exists (maybe not 100% plug and play, but close enough) up to significant power levels, let's say 1000whp on E85. Then it goes back to who will tune it. It does seem like there is one mainstream tuner right now who is willing to go a little outside the box on certain hardware choices, including fueling from what I have seen. The DW400+BAP is absolutely the easy button for up to 800whp or so on E85.

The DW810 looks like it can supply a ton of fuel, but I have a few concerns with some non-performance things about it. The older DW brushless pumps, like the DW440, were known to have some issues with starting the car on the first button press and also basically completely losing remote start because the controller doesn't boot up quick enough. I don't know if the DW810 controller has improved this, but it would be something I would need to investigate before getting it. In all reality, the same concerns hold true for the E5LM+controller and/or the ID BPC100...I would need to know how quickly the controllers boot up before dropping the money. This may be meaningless for some people, but it's a dealbreaker for me.

If I were putting a more capable fuel system together for my car today, and I didn't have any concerns about the controllers for the brushless pumps, I would get a DW810, a Radium bucket, and a -8 feed line with filter running in a return-less config. I am not certain my wallet would be able to find the limits of that setup, which is likely well into the range of needing an upgraded short block.
I will send out emails regarding these questions & see what they tell me.
 
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NGOT8R

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Update from VaporWorx:

Hey Adrian,

I’ve not dived into the Ford driver modules. Do you know if the positive side to the fuel pump is pulsed or the negative side? I can do either way.

Your other questions:

1. Can you build/configure one that will provide a quick reference to show if/when a pump has failed (such as optional wiring leads that can be connected to LED lights on the dash that will illuminate when there’s a failure on pump A, B or C)?

RE: A set of wires can be run from the VaporWorx controller to a dash mounted light that will indicate when the VaporWorx controlled pumps go on/off. The Ford FPDM may have diagnostics for if fuel pressure is falling excessively but cannot point to which of he three pumps is the issue.

2. Does it come with all of the necessary wiring?
RE: Yes. One part is not in stock and will take about a week to come in.

3. How does the system tie into my existing factory fuel pump driver module?
RE: See here. Just need to confirm if the FPDM is a positive or negative pulse. If positive pulse then it will be one of the kits on the webpage based on the engine MAP sensor. If you would rather not tie into the engine MAP sensor then a stand-alone MAP sensor can be supplied for $75 that includes a mounting bracket, hose etc.

https://www.vaporworx.com/shop/product/ally-auto-on-pwm-fuel-pump-controller/

4 . Are there any other components needed?
RE: Whenever a returnless system is use a safety overpressure valve is needed. Please see here about 2/3 down the page:

https://www.vaporworx.com/resources/fds/4-fuel-pressure-regulators/
 
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NGOT8R

NGOT8R

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Does anyone know with absolute certainty whether the positive side to the Gen. 3 fuel pump is pulsed or if it’s the negative side? A fuel system wiring diagram might also be helpful. Thanks in advance to all.
 
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NGOT8R

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The X3 looks to be a very well thought out kit. It includes all of the necessary fittings, pressure regulator, gauge, filter, fuel level sensor etc.

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GL95

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Interestsd to see if you get the barking seal from your regulator
 

cbrtrx

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The X3 looks to be a very well thought out kit. It includes all of the necessary fittings, pressure regulator, gauge, filter, fuel level sensor etc.

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Those 3 fuel intakes do they have any plungers or trap doors on them or are they just open holes?
 
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NGOT8R

NGOT8R

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Those 3 fuel intakes do they have any plungers or trap doors on them or are they just open holes?
Yes they have one way plungers that are included in the hardware kit with the lines and clamps.
 

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cbrtrx

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They’re supposed to have these rubber check valves in them.
That makes sense to have them. Still though with how short that bucket is and with 3 large body pumps in it I wouldn't feel comfortable going wot with too much less then half a tank. I actually think that metal bucket is going to hold in all the heat those 3 pumps produce where as an open setup would probably at least allow for cooler fuel. I think that bucket is just a selling point for them with no real benefit. The radium bucket for example is probably 2.5 times larger then that one.
 
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NGOT8R

NGOT8R

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That makes sense to have them. Still though with how short that bucket is and with 3 large body pumps in it I wouldn't feel comfortable going wot with too much less then half a tank. I actually think that metal bucket is going to hold in all the heat those 3 pumps produce where as an open setup would probably at least allow for cooler fuel. I think that bucket is just a selling point for them with no real benefit. The radium bucket for example is probably 2.5 times larger then that one.
I’m still hoping to pair the system with VaporWorx’s offering as well. I‘ll need to find the answer to their question of whether the positive side to the Gen. 3 fuel pump is pulsed or if it’s the negative side? Once I get that info I will reach back out to them and let them know. They said they can configure it either way.

I want to only run on one pump for normal driving and program the other two to activate when there’s a demand for them. That should help keep the heat down and extend the life of the pumps. This is all new stuff to me, so I’m deferring to the people in the know for guidance.

I also need to determine whether the PCM already has a MAP signal or if I’ll need to run a stand alone MAP sensor.
 
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cbrtrx

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I’m still hoping to pair the system with VaporWorx’s offering as well. I‘ll need to find the answer to their question of whether the positive side to the Gen. 3 fuel pump is pulsed or if it’s the negative side? Once I get that info I will reach back out to them and let them know. They said they can configure it either way.

I want to only run on one pump for normal driving and program the other two to activate when there’s a demand for them. That should help keep the heat down and extend the life of the pumps. This is all new stuff to me, so I’m deferring to the people in the know for guidance.
Yes having one pump running will definitely keep the heat down and all 3 pumps running at wot will provide you with plenty of fuel. My only concern with that setup is going wot with too little fuel. I probably wouldn't go wot with too much less then a half a tank. For example I have the radium bucket with a much greater capacity fitted with 2 pumps, it works well but anything less then a 1/4 tank of fuel wot it will drop pressure like a rock and go lean. It drains the bucket dry even with the return feeding right back to both pickups. Cruising around I can run it to empty just like the factory set up no issues.
 
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NGOT8R

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Yes having one pump running will definitely keep the heat down and all 3 pumps running at wot will provide you with plenty of fuel. My only concern with that setup is going wot with too little fuel. I probably wouldn't go wot with too much less then a half a tank. For example I have the radium bucket with a much greater capacity fitted with 2 pumps, it works well but anything less then a 1/4 tank of fuel wot it will drop pressure like a rock and go lean. It drains the bucket dry even with the return feeding right back to both pickups. Cruising around I can run it to empty just like the factory set up no issues.
Copy that. I’ll make sure to stay topped off when running hard..
 
 








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