Current best solution for fuel pump bulkhead connection?
 

Howdy guys -

One of the guys here in town (Jason) has his fuel pump connector (the small blue connector in-tank) go flaky the other day when he came over, car wouldn't even start. We fiddled with it and got a good electrical connection but it doesn't give me a good feeling that will be a long term solution.

My car has been running a Walbro 255 since for damn ever and the pump is rewired up at the front of the car, just giving more voltage to the circuit opening relay. Never had a problem but I want to insure that stays the case.

So, here's what I'm looking for -

- Something that will use the stock wiring into the hatch, just bypassing that crap tiny blue connector on the top of the fuel pump assembly. There's no need to replace all the wiring for 1 Walbro 255 and I want to keep the stock 9v/12v dual speed setup.
- Something that is foolproof and won't leak or wick up fuel.
- Must be wiring rated for in-tank use
- If I'm drilling a hole in the top of the hanger, I want to drill it ONCE, it be good, and never mess with it again.

The best option I've found so far is the Radium setup -

Bulkhead Fuel Pump Harness and Connectors

Very nice but DAMN, close to $150 for the in-tank harness and external harness. But, I like that it's very well designed and quality. I don't mind paying for quality but I also don't want to pay for something that's just overpriced.

I also want a good, sealed connection on the outside of the pump hanger. Some are just exposed studs with a nut and a crimp-on connector. That will work for a while but an exposed connection like that in atmosphere can corrode over time. There's a reason Mazda used a weather tight connection.

Any input?

Dale

Dale,
Here's my fix for the bulkhead connector when running a bigger fuel pump (mines a Walbro 450)
Reading up and noticed lots of people have ran into problems with the stock connector getting hot and burning because big aftermarket pumps pull way more juice than a stock pump and the stock connector doesn't like that...lol
Its a ATL bulkhead connector...... All wired up with 10gauge PTFE wiring and PTFE butt connectors.

ATL Fuel Cells CFD-504 ATL Electrical Bulkhead Fittings | Summit Racing

Ive been running it for over a year.... also I just checked it last month before heading out to DGRR.... Zero issues!


https://cimg8.ibsrv.net/gimg/www.rx7...a0b47ade32.jpg

https://cj-motorsports.com/products/...-weld-in-6-way

I used this one mine and it worked good.

Mine is very similar to this, I used a fuel cell gland to run new wires to the pump, works great.

@estevan62274 where did you get the wiring and connectors to go through that bulkhead fitting?

I thought some people were having problems with fuel wicking up the wire with similar setups, this may be due to using the wrong wire, though.

Dale

@DaleClark I bought them from eBay.
Make sure its PTFE wiring and butt connectors which is made to be submerged in fuels. :icon_tup:
Yeah, I believe the wicking is from using the wrong wiring and/or butt connectors.
I've checked mine several times in the last year and its all good, no wicking, leaking, or anything strange going on with the connector/wiring.

Steve, I’m going to go your route with this, I put the bulkhead adapter on order how much wire will I need?

Thanks
Jason

Hey man, I used 2ft of wire and it was plenty.:icon_tup:
Steve

Thanks Steve.
Sounds easy enough, looks good and gets the job done. My kind of fix.

Jason