Post here if you are interested in a bolt-on kit.

what are the benefits ????

Yes Please !!!!!!!!!!!!!!!!!!!!!

interested...thoughts on price?

wow thatd be awesome

that would be amazing! id buy one first day they were on sale if i knew about it!

im intressted..that will lower chances of blownin motors..

to be honest not one of you will need it. this does not make the car any safer. unless you plan on pushing 400 + whp you wont need it

to be honest not one of you will need it. this does not make the car any safer. unless you plan on pushing 400 + whp you wont need it

with ur tune and my stupidy ill be real close

So what pump you going to fit in the stock canister? BTW, what do you exactly mean by "bolt-on" for a new fuel system?

Def. interested if its a good price, otherwise ill do it myself.

haha nope i push my car hard with no problems. i have been running a 2.5 since the car had 400 miles and that was 2 years ago

I am in like flinn.......

i'm interested, how much money are we talking for this setup?

Looks like a good response so far, the details for the kit are up in the air actually. We've got a kit designed for Rod's 1200HP car, but, this again is a fuel cell w/two pumps and custom fuel rail, etc... We'll think over the stock in tank unit design and see what we can do about the fuel pump in the tank and come up with a design in the next couple weeks with pricing.

interested

Depends on price and how much "blot on" there is

I think you should try to just run a line for the stock pump and have a bolt on pump fitted to the body! That way we can upgrade the pump later on without removing the fuel tank! I think it would make everything about the return system more of an option!

Also maybe with the kit add a bigger fuel line to the system! for us pushing the cars to 500s or so!

this is something i might be interested in doing but i would like to see how upgradeable it would be since my car is stock right now but i plan to do some major mods

I am intersted in this as well

Very interested here... I may not necessarily "need" it but i'd love to have a bit more piece of mind :)

Well guys, here's the low-down:

Jason and I were talking about the entire system design using our tester car (Thanks again for the couple days of use player_1) and we'll again investigate more possibilities but making a bolt-on kit for an inexpensive price seems far fetched.

Here's the many issues along the road to making the kit bolt-on, and this is where we need feedback from the community as how to cut costs and realize how much "work" the end installer is capable of or wants to do. Also, if you're going to upgrade to a return system, you're probably going to want to increase the feed line diameter, doesn't make sense not to.

So let's start with the extreme, a full bolt-on kit:

This means, no drilling, no modifying (very little anyway), or cutting. Just install in the below new units and off you go.

Here's what we realize what you'll need in order to have a full bolt-on kit,

Full Bolt-On Kit


Custom Fuel Pump (Hi-Flow Hi-Pressure)
Customer Fuel Rail (More flow, customizable for off-sized injectors, NPT fittings for new stainless lines)
Custom Module Assembly (Hanger for new Fuel Pump, Fuel Sender, Float, EVAP line, NPT Fitting for feed & return, Tank Pressure Sender and Wiring for pump)
AFPR (Self-Explainitory)
High Flow Fuel Filter (Billet unit)
Around 10 Aeroequip Fittings
Stainless Steel Lines, feed & Return (or even nylon up to a point)


As you can see, this is expensive... Hella, expensive. But everything will work with the stock oem components, emissions and won't require modification by the end installer. So if you just sit back and throw some numbers out for the above components, we're approaching the 1500 mark! Fuel pump: $250, Custom Rail: $300, Custom Module: $300, Lines, fittings, AFPR, high flow fuel filter, things we forgot to mention or even think of: $500 ... Would people be interested in spending that much?

Custom Module Assembly Only

Another option is to make the custom module assembly, such that you can be the one to sweat the rest out, buy the components as you need and make your own fuel rail. The module assembly will have the provisions for NPT fittings and come with a new high volume, high pressure pump. Then, you take care of everything else. Where all you need to do is run whatever lines you need, figure out how to put them into the stock rail, figure out how to put the fuel filter, etc..

External Reservoir System

Another option is to make an external reservoir system, such that the end user installs a feed line into the existing plastic tank, and the external reservoir system will have all the aftermarket components for feeding and returning the fuel and leave the stock emissions, float and other tid-bits in the stock tank. This option scares me, but its an option nonetheless...

This is what we came up with... now we need opinions. Again, the first scenario, where we do all the work is ideal, but again unless there's a strong following, we can't work the price of units if only 2 or 3 are sold / year.... people have to dedicate to the project if they want something for a reasonable price where we can churn out 20 units and get a discount rate purchasing all the components from the warehouse and bring the MSRP well down under $1500 bucks.

Eh, my opinion is thats just too much to spend on a fuel system conversion. Most of us that have done it on a car whether Cobalt or not can usually fab up something of decent quality for a third of the price, a tuning shop usually for half of that installed.

You are speaking of parts such as a 300 dollar custom module, 300 dollar custom rail and such, which would be ideal for a 600+ horsepower race car but you are targetting the system to a 300-400 MAX hp daily driver for most. What would be wrong with fabricating a kit with off the shelf GM ecotec return fuel rails and finding a pump that flows the equivalent of a walbro 255 or more that would actually fit in the stock fuel module? (there is one out there and it costs ~100$, made by Walbro used in certain OEM applications)

I think the overbuilding and subsequent high price will deter many into building a custom system for their needs, in my humble opinion.

I'd have to agree... for 1500 I wouldn't be interested... I'd like some piece of mind but that's just a tad steep for me. I know these things cost money but as WITT mentioned it would need to be much more cost effective for the interest to be strong with the Cobalt/Redline community.

i agree most people are looking for a system for a 300-400hp cobalt...

this is going to be expensive

... budget system;

- nylon return fuel line
- nylon rail to FRP line
- FPR
- Fuel pump
- tapped OEM fuel rail (send in stock core)

Price?
less than $400

Then most people are interested in a budget system... That basically gets the job done for under 400hp. So let the interested people show some more support and lets build the system piece by piece together. That way we can make the system the way you want it..

tapped OEM fuel rail (send in stock core)

not too big on this idea. After looking at the stock rail, It's big, but its tricky to tack an FPR on the end of the unit or on top. Hood closure issues come to mind and fuel line routing.

- nylon return fuel line
- nylon rail to FRP line

Cheap, gets the job done.


Eh, my opinion is thats just too much to spend on a fuel system conversion. Most of us that have done it on a car whether Cobalt or not can usually fab up something of decent quality for a third of the price, a tuning shop usually for half of that installed.

Usually the systems that we make are show pieces.. We like to use the best materials and quality parts. In this case, people aren't after that... They just want it to work, and work well. We can do that.. it just takes a little more prying of our pride.

What would be wrong with fabricating a kit with off the shelf GM ecotec return fuel rails

Nothing, thats a great idea. I'd just like to be able to give people some options. How about we twist everyone's arms in spending a little more for stainless lines as opposed to nylon?

walbro 255 or more that would actually fit in the stock fuel module?

There's a bunch of pumps that will fit into the stock fuel module. This means that people will be stuck at the current line diameter (3/8's I believe)... It can be done, reluctantly, but can be done. It will bring costs down considerably.


Anyone else care to add/remove components to the system?

not too big on this idea. After looking at the stock rail, It's big, but its tricky to tack an FPR on the end of the unit or on top. Hood closure issues come to mind and fuel line routing.



Good point.
I assume you'd be looking into a small diameter flow though style... probably made of generic fuel rail stock.
I know Venom makes an aftermarket flow though fuel rail for the Ecotec... it might be worth looking at to get some ideas.

I am DEFINITELY interested in this. this is a part our cobalt community NEEDS. A return fuel system is a need. Thanks for doing this JBP.

i think most people, includung myself, just would like to get the job done. It doesnt have to be pretty, its under the hood, but would also like it to be reliable for a 300-400hp car...

Ok guys, so here's the final cut. There's the problem of the return line. There's an issue that we don't want to be apart of, and thats the return line to the tank. Some how you're going to have to get that line into the tank to return fuel. This means, making a hole in the tank or the sender unit or whatever... This just screams "liability issue" to me.. It's not fool proof and we're not going to discuss how you should go about doing that.

So the system will consist of the following:

1) In Tank, Fuel Pump
2) Stock FPR Delete Kit
3) Modded Fuel Rail with Nylon attachment
4) Aftermarket AFPR

Ok guys, so here's the final cut. There's the problem of the return line. There's an issue that we don't want to be apart of, and thats the return line to the tank. Some how you're going to have to get that line into the tank to return fuel. This means, making a hole in the tank or the sender unit or whatever... This just screams "liability issue" to me.. It's not fool proof and we're not going to discuss how you should go about doing that.

So the system will consist of the following:

1) In Tank, Fuel Pump
2) Stock FPR Delete Kit
3) Modded Fuel Rail with Nylon attachment
4) Aftermarket AFPR

How about a 3/8" quick connect fitting plus fuel line to couple with the return line already installed between the fuel pump and tank?

How about a 3/8" quick connect fitting plus fuel line to couple with the return line already installed between the fuel pump and tank?

Can you elaborate your idea. Not sure what return line you're talking about.

Can you elaborate your idea. Not sure what return line you're talking about.

There are two lines between the fuel module and the fuel filter, one is a supply and one is a return (marked on the top of the fuel module as "S" and "R" and also color coded at the quick connect fittings). As the fuel pump feeds an unregulated amount of fuel to the filter, the filter returns fuel to both the fuel rail and the tank. The return line from the filter to the tank is where the stock fuel regulator is located. By removing the stock fuel regulator you leave a return line from the filter to the tank that can be tapped as a rail return by extending this line from the filter to the engine bay. The filter is a stock "1 input, 2 output" type filter, one output going back to the tank's regulator and one to the fuel rail. This in any case needs to be replaced with an off the shelf GM "1 input, 1 output" type fuel filter which will leave you with the stock return line to do as you wish.

http://www.cobaltss.net/forums/showthread.php?t=88023&highlight=return+fuel+rail

Just for reference.

http://www.cobaltss.net/forums/showthread.php?t=88023&highlight=return+fuel+rail

Just for reference.

In that link, he removes the stock return line. What I was saying was to retain that line and use a quick connect fitting (to couple to the blue female end you see in the pictures) to extend the return line to the engine bay.

In that link, he removes the stock return line. What I was saying was to retain that line and use a quick connect fitting (to couple to the blue female end you see in the pictures) to extend the return line to the engine bay.

Either way works.
It's not like the quick connect fitting are really expensive... I think Summit sells them for about $5 each.

sorry guys, a turn of events in a project has left internet time sparse. Ok, so if there's a return line from the filter to the tank, then realistically what does everyone need us for? :) All we'd do is match up the same parts that are available already in one convenient package and provide the instructions that are listed in the how-to... Seems to me that everyone can put together their own kit, no?

sorry guys, a turn of events in a project has left internet time sparse. Ok, so if there's a return line from the filter to the tank, then realistically what does everyone need us for? :) All we'd do is match up the same parts that are available already in one convenient package and provide the instructions that are listed in the how-to... Seems to me that everyone can put together their own kit, no?

People want things like the SRT-4's have. They want a kit that comes with EVERYTHING needed to put a return fuel system to use. Instructions, parts, everything. So anyone who doesn't have a know how can just come to you all and get what they need.

sorry guys, a turn of events in a project has left internet time sparse. Ok, so if there's a return line from the filter to the tank, then realistically what does everyone need us for? :) All we'd do is match up the same parts that are available already in one convenient package and provide the instructions that are listed in the how-to... Seems to me that everyone can put together their own kit, no?

True but like said before, some of us don't have the mechanical sense to put something like this together and make it work. Naval weapon defense is my daily job, but formulating a plan for a return-fuel system is a little complex for me at first. I'm not trying to make something that will be outrageous and way more than I need. Most, including myself are looking to be in the 300-400hp range. You would know better than I how to set up the proper system.

we'll make it if there's a demand for it. ;)

Give us an idea of what would be a package for a return system would look like.

subscribed and interested

Figured I'd drag a dead topic up since no one has said anything in 2 months. Whats the deal with this, did demand go away?

Figured I'd drag a dead topic up since no one has said anything in 2 months. Whats the deal with this, did demand go away?

over the top performance already makes a kit......PM fast98 or lsjwannabe