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CJ5 wild stretch and full build (Big Booty Judy)

More work on the cell. Didn't have the right size hole saw, so I had to do it the old fashioned way.
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Inlet, inlet vent, primary suction, secondary suction and return in.
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baffled the return to dump with minimal foaming by the suctions
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all the baffles in, and the tube for the level sender (hopefully to keep it from bouncing too much)
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Diffuser over the pick up socks and the center splitter.
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In the skid plate
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At full stuff. Tight, but plenty of clearance.
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More tank work. Machined some stainless aircraft fittings to make adapters for fuel pump pickup socks/filters. This puts the pickup 1/4c off the bottom of the tank.
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Primary/secondary fuel pump pickups (running a spare line/pump/filter setup as an easy switchover backup system) return runs over the baffle into the main tank section.
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Everything tie wired into place to prevent fittings from loosening up. All stainless 304 lines with aircraft fittings and soft seats.
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tank top access panel. Not ideal, but will serve my purpose.
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had to relocate the return fitting (too close to the upper link for comfort)
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Initial pump pickups, with outlet side free flow aircraft check valves (no back flow through the pumps and should keep the lines pressurized and primed)
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pump pickup socks installed under the baffles. At roughly 1/4" from tank base. Fuel sender is 14" read capability, tank is 15.75" deep. So even at empty I should always have fuel in the tank.
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top plate coated in aircraft gasket maker. Nasty stuff, but it has never failed to seal for me.
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Lower retainer/captive nut plate. Goes inside the tank. Gasketed top and bottom and bolts every inch shouldn't have an issue sealingat atmospheric pressure. Gasket was relieved for the nutsert tops so it should fully pinch the gasket.
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Top plate installed. Used more aircraft gasket maker under the top plate gasket, and under bolt heads to prevent leaks (and prep for final leak/pressure test). Then coated the edge with dupont aircraft fuel compatible rtv.
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then started making some stainless tank straps and gave up for the night.
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We scrapped an old project at work, so I had to strip a bunch of panels and scrap the fittings as they could no longer be used as new. I asked management if I could keep everything stripped, and they agreed so I ended up with a giant stockpile of lightly used 1/4" through 1/2" aircraft AN fittings, tubing, nuts, sleeves etc. So everything is getting 1/2" stainless hard lines for the fuel system and aircraft rated parts. Makes for peace of mind and really reduces the likelihood of fuel system leaks.
 
Little bit of progress. Both pumps (jegs house brand 320LPH/85GPH 90 psi) installed with outle checks. Inlet is O-ring boss, outlet is metal to metal. Not sure how I feel about that. We'll see I suppose.
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plenty of link clearance through travel.
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i initially was going to use 2 corvette filter regulators with combined returns. Don't like it, too complicated. Decided to go a different route. Inline 50 micron filters on both pumps to a single fuel lab regulator/single return line with a boost sense port. Will greatly simplify my plumbing and packaging. So these filters are coming out. Anybody need em? I put the -8AN adapters on them. 100 plus shipping and they're yours.
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Spent the day on Judy yesterday. Fuel cell is finally a wrap. Pressure test went well, only three very small pin holes in all those seams, a couple spots re-prepped welded, then a retest, all good. I was very concerned with the large flange/access panel, but it passed with flying colors. Finished the skid plate completely, flushed, smoothed a ground all welds i could access and was finally able to bolt everything into the frame. Made a couple stainless tank straps to keep everything snugly in place and then started on the fuel pump mounts. Overall an extremely productive day as I can now begin the rest of the fuel system plumbing. Really happy with how it turned out. Also swapped the corvette filter regulators for billet filters and an external fuelab regulator with a boost sense port. Will help clean my plumbing up and simplify installation.
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Good ol soapy water tattle tale test.
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cheap low pressure tank test rig..
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Two small pin holes next to each other. Was surprised, the bead looked good in that whole area.
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One small hole in a corner. Not too surprised there.
 
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Tank finished, washed and drying prior to install.
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Skid plate mounted to the frame on its own finally.
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Used weld inserts and 1/2-20 bolts to keep it in place.
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1/8" rubber mat under the tank and straps to protect the cell from abraisions.
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Made some adjustable tank strap tension mounts to make sure it can't wiggle around.
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Fully protected
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Ans started on the pump mounts with these trick little band clamps.
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Pretty stoked for this little part. It's just a fill tube and vent line for the rear mounted fuel cell, but, everything fit and cleared all the suspension, I have plenty of drop so I shouldn't get fuel back up while fueling (the secondary fuel fill vent will help as well). But the best part is that I'll be able to use the stock fill location by the drivers door and keep the classic cj look, without having a gas tank under the drivers seat. So I'll have more capacity, be safer, and won't have to smell fuel in the cab. All 304 stainless so E85 shouldn't be an issue.
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Made some beading pliers to bead the tube.
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That some damn nice well thought out work right there. Well done Sir.

I fully understand wanting to use the stock filler location. It's those little things that make a build like this so cool.
 
Totally understand life's other things sometimes take precedence and the funds thing is hard to escape!! Well we will be here waiting for the next round of updates when they happen.
 
I started plumbing the fuel system again
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Got to here, and though the plumbing job wasn't terrible, it wasn't great. I didn't like it. So I ripped it out today and started the post filter section again.
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So i dug through my fitting horde, found some bulk heads, a couple more unions, and tightened the whole package up.
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everything is all stainless AN -8 (1/2). Theres a filter screen, to a short pickup, to the pump, through a check valve, into a 15? Micron fuel filter. With one pump acting as the primary pump, the other as a backup or if the fuel pressure drops due to demand (there will be a pressure switch mounted on the frame rail and if pressure drops below 50psi the secondary pump will kick on). The bulk head plate has outlet fittings for fuel and return fittings. You can also see the first section of return line installed here.
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Then I gave up for the day. I need to order my e85 sensor fittings and figure out where to run the end of the hard lines before the ptfe hose (for flex) goes to the engine rails.
 
A little progress today. E85 sensor installed, and tubing plumbed to the sensor.
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nifty little thing too. All e85 sensors a 3/8" tube. So if you get into high horsepower/ fuel flow and want to run e85. They end up choking at the sensor. A lot of companies make these dual pass tubes that you can install a stock gm sensor in but have a 5/8" bypass tube to prevent flow limits, all contained in a single housing with single inlet/outlet up to a -10 (5/8") fuel line. This is another reason for as much stainless line as possible. No corrosion issues with corn fuel.
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Simple'72CJ said:
Damn! Wanna come build my cell and fuel system? :lmao: Looks bitchin!!!
Click to expand...
I would. Wouldn't be cheap though. The fittings alone would cost a fortune. Only reason I have em is they were being scrapped as "used". Most of those swivel fittings are a couple hundo each when new. Ridiculous.
 
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