My dad and I have been playing with the idea of installing fuel injection in the Maverick for a long time and have built a MegaSquirt module as well as procured the intake manifold (including fuel rails and injectors) from a '92 Thunderbird 5.0 HO and there is only one last issue to be dealt with: Fuel delivery. I'll need an electric fuel pump (I'll be using an in-line most likely as this seems easiest) but the return line is what we suspect will be a small issue. I'm thinking of finding another Maverick fuel line and installing it parallel to the original, but how should one go about delivering fuel back into the tank? Drill another hole in it?
i have had good success with punching a hole in the tank then taping the punched hole with a pipe thread tap. then i will put a fitting with the correct size thread into the hole with red lock tite on it. i have never had any of them leak. its a quick and easy way to put a return into the gas tank.
If you dont want to do any drilling on the tank or anything you can run a moroso return line kit that connects too the filler neck hose. http://www.summitracing.com/parts/MOR-65385/ the only problem with that is you would have to run the return line into your trunk.
How about using the line that is on the firewall that goes back to the tank and sits on top as a breather or what ever its used for? That way theres no runing or drilling just run a rubber hose to the metal line.
That's how mine was ran, I did have to drill the "vent" at the tank bigger in size but no issues. Vented gas cap is required
for my return line, i drilled a hole in my sender unit and made a 3/8 return nipple and welded it in. worked well, hardest part is to keep the heat down on the welder so u don't damage the plate or anything on the sender.
I did this as well, and also drilled out the vent on the top of the tank. Fuel pressure can spike and you can blow the rubber lines if you don't drill out the vent. I also have a vented cap. I've been running this way for years with no problems.
i removed my vent in the top of my 73 gas tank and took a stock mustang pump assembly bent it just a hair it set right in the hhole sealed with the factory maverick ring and solved the fuel pump, and both fuel line problems
is the motor effected by fuel slosh as the fuel level goes down. the stock ford efi gas tanks has a baffle system in them that helps trap gas around the pick up when the fuel level is low.
No poblems so far. Of course my gas hand doesnt work so i tend to keep it around half a tank but i see where it coukd be a potential problem but the pump sits at the bottom of the tank as well. Ill find out soon enough
