Muscle Mustangs & Fast FordsProject Vehicles
1988 Ford Mustang GT Project Hypersilver - Fuel System and Wiring
Fuel and Fire
When you think about fuel and electrical systems, it's hard to picture them working together—at least, without catastrophic results. The truth is, though, one needs the other to operate properly, especially when it comes to Mustangs and other late-model Fords.
Fuel is supplied by an electric pump and (most of the time) injected into the intake manifold through electronic fuel injectors. And without that jolt of electricity, no fuelly and no runny.
With Hypersilver, almost everything is electronic, including the fuel supply. We turned to Aeromotive for some of its tried-and-true components to deliver fuel from our ATL fuel cell to our Jon Kaase Racing Engines 427. We combined the 340 Stealth pump with its inline fuel filter to provide 340 lph of 93-octane to the fuel rail that our Borla Induction intake system was already equipped with.
Pump It Up
Aeromotive offers a wide array of fuel pumps, cells, pressure regulators, filters, rails, hose, fittings, and other components. It develops and manufactures these components in its Lenexa, Kansas, facility, and even creates specialized components for drag racing, circle track racing, off-road, marine, street rods, and muscle cars. One of its most successful and widely used lines is its Stealth system.
Designed for mild-to-wild builds and everything in between, at the heart of each Stealth system is the Stealth fuel pump. Manufactured as a direct replacement for most OEM fuel pumps (including Mustang), the Stealth 340 (about $175) is the dynamite of fuel pumps. It's packaged like a wimpy stock pump, but offers up to three times the fuel. “The 340 Stealth pump will deliver 340 lph, or enough for up to 700 naturally aspirated horsepower,” Jesse Powell of Aeromotive says.
And since we had already decided on ATL's 15-gallon sport cell, we had Aeromotive ship our Stealth pump directy to ATL's manufacturing facility in New Jersey. There, it was installed and pre-wired before it was shipped to us. So when we received our fuel cell, we didn't even have to open it. We just bolted it in place, and all that was left was to wire it, attach the fuel lines, and fill it up.
To deliver all the 93-octane unleaded gasoline that our 427 will ever need is a full set of custom fuel hoses, courtesy of Aeromotive. This braided stainless steel AN line is perfect to complement our pump and 100-micron filter. The most audacious task of installing the system, though, has to be making the hose ends. But once you make one end, the rest are easy. It just takes a sharp cutting tool, some time, and a bit of patience.
Cool As ISIS
Instead of replacing Hypersilver's wiring harness with a stock replacement or other traditional aftermarket harness, we turned to ISIS. The Intelligent Multiplex System is a simple, flexible alternative that eliminates the need for relays, fuse blocks, and fixed functionality. That's right, programmable (and re-programmable) functionality to control things like door locks, window motors, radio, lights, horn, and anything else that is electrically controlled.
The possibilities are endless, and the amount and level of difficulty of the functions that we're using on Hypersilver won't even begin to test the capabilities of the ISIS system. These things are used in things like limousines and buses, so we're just scratching the surface.
01. This month, we’re tackling the fuel and electrical systems of Hypersilver. Here’s our complete fuel system from ATL and Aeromotive.
02. The 15-gallon ATL Sports Cell that we chose features a lightweight aluminum frame, internal surge tank, offset remote-fill paddle valve, and is compatible with race gas, pump gas, and ethanol.
03. We requested that Aeromotive ship our pump directly to ATL, where the pump was pre-installed in our fuel cell. All that we needed to do was wire it up.
04. Once the cell was mounted, we began routing the fuel lines. Making the hose ends is the most daunting part of this install. After deciding length, we wrapped the hose with masking tape and made a straight, clean cut with a cutoff wheel.
05. Sometimes the burs need to be taken off before removing the tape.
06. Then, we carefully removed the tape. Even though it looks smooth and harmless, the end of the hose where we made the cut is sharp, and will draw blood. Don’t ask us how we know.
07. The sleeve is the first part to go on.
08. We then taped over it to protect it from our tools.
09. We then lubricated the fitting with a multipurpose lube and started the threads by hand.
10. We used a vice and open-end wrench to fully seat the fitting.
11. We then found a suitable home for the inline filter next to the right rear framerail and mounted it using the supplied billet aluminum mount from Aeromotive.
12. Drilling specialist Darrell Kunda blew some holes in our inner fender to mount the bulkhead fittings, and then we just connected the dots with the fuel hose.
13. In the wiring department, we went with this complete kit from ISIS.
14. At the heart of the ISIS system is the Mastercell. It receives ground signals provided by inputs (switches). It contains all of the programming, and when commanded according to predetermined settings, sends signals to the power cells, which then send power to the components.
15. Wiring prodigy Kunda tied all of the provided ISIS harnesses to our components.
16. Kunda had to use the OEM wiring harness to salvage certain pigtails, which he then tied into the ISIS system.
17. He then installed new components like turn signal switches, door lock switches, and power window switches.