Well I'm making changes on the car and really would like some input.

13B Street Port Medium
BW S366 Turbo
Micro tech Standalone

I'm looking for the best setup to make up to 500hp on E85. I don't see myself making that but its the bench mark where I want to be at.

Fuel Setup currently

Primary 2 ID1000
Secondary 2ID2000
CJ Motorsport Fuel rails
-6 on the rails with Aeromotive FPR
Walbro 485LPH (e85 comp) Rewired

But not sure what fuel line diameter or if my pump will be sufficient up to those power levels. I was thinking -8 feed and -6 return or leave the stock return. Also what do yall recommend for what kind and size micron fuel filter should I use.
Any advice is appreciated. thanks

I am trying to do what it takes not a overkill.....

 

I would go
4x2000cc
8AN feed 6AN return.

I use a Magnaflow MP7010 25 micron post pump.
DO NOT get the cheap 20 filters from ebay. get a filter with a large surface area.

Here is good information about filters
Pre-Pump Fuel Filtration - Aeromotive

 

the only thing i would suggest is to add a 2nd pump, and crank up your base fuel pressure to atleast 50 psi, and crank up the boost. your setup is almost exactly like mine and i haven't had any issues so far, i don't think i have 500whp though, but im sure i could with the right tuner behind the laptop, im a novice lol

 

I'm one step ahead of yall bought these parts already!

-8 feed
-8 return
10 micron SS element
dual 485 pumps
Y block at rails and on pumps

 

I went with a 4" downpipe on the bws366 what are using?

 

I'd start with what you have and see what it can do first before swapping things out.

If injector duty cycle is too high swap out the 1k's with 2k's
If fuel pressure is dropping under load then I'd look into -8 lines / additional fuel pump as needed ... -6 will support 500 if the pump can handle pushing enough fuel ... -8 just makes it easier on the pump as there is less restriction.

Dual Walbro E85's should support around 1200 hp running E85 based on this:
Radium Engineering - Tech Articles
They state they will support 831 hp on E85 (boosted) ... adjusting for rotary ( divided by 1.3 ) gives around a rating of 625 hp.

 

I assume you are saying 500rwhp, and not 500bhp. 1000/2200cc will be enough on e85 for 500bhp, but might not be enough for 500rwhp depending upon how much torque the engine makes. 500rwhp and 500ft lbs of torque is a lot different than 500rwhp and 380rwtq.

You are better off using 4 Id2000s, and a base fuel pressure of 43.5psi. Most pumps don't flow a lot at higher pressures, so the higher your base fuel pressure the more the pump will run out of steam when the boost is high.

-8 feed with a big single pump is the preferred method with
75 micron pre pump & 6 micron post pump fuel filters

I would also advise using an ECU that supports flex fuel, as the E85 content varies a lot from the pump, which will throw your tune out the door..

 

i went with a 3.5 inch downpipe

 

I'm working on changing to (4) Id2000 instead I really don't want to run higher then 43.5 base pressure.

I only have one pump station that I have access to locally. But regardless I plan to just test the ethanol with a test kit.

I think when you jump to different pump stations and season change that alone has the biggest effect on e85.

I'm aiming for 500whp and will turn up the boost until I get there that's the goal. Hopefully I can do it under 24psi.

The motor was closed a couple of weeks ago I'm very happy with the quality on the rebuild. This by far is the most aggressive build done yet.

I've ran E85 before so I'm familiar with it.

 

I think I could of went 3.5 and have the same results on the dyno. I just wanted to make as much hp as I can. But I doubt it makes a difference though!