'the Other Bosch 044 Intank + Bnr32 Thread'

[GeeTR]

Was going to see if Saliya wanted to add this info to his thread, but hes been absent from SAU for a while now. Thought I will make my own. I figure when your in dire need for a DIY, you cant have too many

Ill assume you know how to do all the basic removal stuff from Saliya's thread. Im concentrating here on the points that took me most of the time and thought with installing the 044 in the stock position.

Below is 12mm metric fitting. I forget what the other end is, doesnt really matter as you'll be machining it off.

Details of pick up fitting I used...

End that screws into pump - 18mm wide, 13mm length from centre with a 11.1mm ID

End that attaches to strainer - 12.95mm wide with a 8mm ID.

In a lath, working on the smaller strainer end, I removed ~2.5mm of material, giving a OD of 10.5mm. This gives a wall thickness of around ~1.8mm. The ID of the strainer is 9.5mm.

I then gave the the last half of the fitting a taper down to 9.8mm. I half sanded down the cutting marks, leaving some roughness for the strainer to grip to.

Below is the strainer after i removed about 25mm of length. I used a hot knife attachment in a gas butane torch to prevent plastic swarf from getting inside the strainer. I used the below check valve (one way valve) with 5/16 hose ends, so i could mount outside the tank if need be (I didn't have to) This also cuts down on the total length of all the fittings on top of the pump. As Saliya mentions, its pretty close to the side of the tank.

Below is the pump cradle trimmed to fit the 044. Comparing this picture to the real thing should make it pretty obvious what needs removing.

Below is the completed setup (bar the one way stuck in the return Instead of using banjo's, nipples and right angle fittings, I wanted to reduce unnecessary restriction, cost and packaging. I found the easiest way to simply use a 1/4 BSP -> -6 race fitting, then a -6 90⁰ bend, then 8mm hose end. Most Speedflow, Earls, AeroQuip are all interchangeable I believe.

Thoughts:

- I wont be able to pressurize the setup for a month or so due to other restraints.

- I intend to be running this pump outa flow in the next 12 months, and install a much smaller Bosch to feed a surge tank; this is why i tried not to damage / modify the cradle in a way so that I couldnt use it like the factory did. I will be sure to update this thread with the 044 @ 13.8v @ XYZBar flow capacity.

- The one way valve looks to have a fairly small ID, so that could be a restriction in the future - we'll find out.

- The strainer does sit a little high (~5mm) but shouldn't make a difference. I could have used some rubber to chuck the pump up a little, as well as reduce noise (Nismo bolt-in user's with their "$420 buys you 20min bolt in, and its soo quiet" made me see if i could mount an 044 just as quietly) but, I couldn't find anything that was GUARANTEED not to break down in ULP. When i do find something (maybe even some excess fuel line, ill mod this post.

- As Saliya's thread mentioned, finding fuel hose thats both buytl inner and outer is 100% required. Iv seen / heard of too many story's of degraded line. I didn't need any extra line here; If i did, i was going to use sections of hard line to extend it.

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Hope this helps!!!

Edited April 2, 2008 by GeeTR