Mercedes Mullins
When building an 800 hp engine running on E85 through a carburetor, selecting the right fuel pump is critical to ensure consistent fuel delivery and performance. E85’s lower energy density compared to gasoline means the fuel system must supply a higher volume of fuel, requiring a high-flow, high-pressure pump capable of meeting the engine’s demands. For carbureted setups, a mechanical or electric fuel pump rated for at least 150-200 GPH (gallons per hour) at sufficient pressure (typically 7-10 PSI) is recommended. Additionally, considering E85’s corrosive nature, opting for a pump with ethanol-compatible materials, such as anodized aluminum or stainless steel, is essential to prevent degradation. Pairing the pump with a regulator, filter, and proper fuel lines ensures a reliable system that can support the extreme fuel requirements of an 800 hp E85 carbureted engine.
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What You'll Learn
High-flow fuel pump options for 800 hp E85 carbureted engines
Achieving 800 hp on an E85 carbureted engine demands a fuel pump capable of delivering massive volumes of fuel under consistent pressure. E85's lower energy density compared to gasoline means you'll need a pump rated for at least 150-200 liters per hour (LPH) at your target fuel pressure, typically 50-70 psi. This ensures adequate fuel supply across the entire RPM range, from idle to wide-open throttle.
Aeromotive, DeatschWerks, and Walbro dominate this high-flow category, offering pumps specifically designed for ethanol-based fuels.
Consider the Aeromotive A1000 as a benchmark. This in-tank pump boasts a 1,000 LPH flow rate, more than sufficient for 800 hp applications. Its compact size allows for easy installation in most fuel tanks, and its ethanol compatibility ensures longevity. Pair it with a fuel pressure regulator capable of handling E85's corrosive nature, such as those from Aeromotive or Fuelab.
External fuel pumps like the DeatschWerks DW65c offer even higher flow rates, reaching 650 LPH, but require mounting outside the tank. This setup provides easier access for maintenance but necessitates additional plumbing and a dedicated fuel cell if your existing tank lacks the volume.
Don't underestimate the importance of fuel lines and filters. Upgrade to AN-sized braided lines rated for E85 to handle the increased pressure and prevent leaks. Install a 10-micron pre-filter before the pump and a 5-micron post-filter after the regulator to protect your injectors from debris.
Remember, fuel pump selection is just one piece of the puzzle. Ensure your carburetor is sized appropriately for the engine's airflow and that your ignition system can handle the increased fuel demand. Consult with a qualified engine builder to ensure all components work harmoniously for optimal performance and reliability.
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Compatibility of fuel pumps with E85 in high-horsepower setups
E85's lower energy density compared to gasoline demands a fuel pump capable of delivering significantly higher volumes in high-horsepower applications. An 800 hp setup, for instance, might require a pump rated for 150-200% of the fuel flow needed for the same power output on gasoline. This is because E85 contains roughly 30% less energy per gallon, necessitating a pump that can compensate for this deficit.
High-performance fuel pumps designed for E85 compatibility often feature larger impellers, high-flow inlet and outlet ports, and robust internal components to handle the increased flow rates and the corrosive nature of ethanol.
Selecting the right fuel pump involves a careful analysis of your engine's specific requirements. Start by calculating your engine's fuel demand based on horsepower, fuel type (E85), and desired air/fuel ratio. Reputable fuel pump manufacturers provide flow charts and compatibility guides to assist in this process. For an 800 hp E85 setup, a pump capable of delivering at least 150 gallons per hour (GPH) at your operating pressure is a good starting point. However, factors like fuel pressure regulator efficiency, injector size, and desired safety margin should also be considered.
Opting for a pump with a slightly higher flow capacity than calculated provides a buffer against potential fuel starvation under extreme conditions.
While prioritizing flow rate is crucial, overlooking fuel pump compatibility with E85's corrosive properties can lead to premature failure. Ethanol's hygroscopic nature attracts moisture, accelerating corrosion in pumps not specifically designed for E85 use. Look for pumps constructed with ethanol-resistant materials like anodized aluminum, stainless steel, or specialized composites. Additionally, consider pumps with internal coatings or treatments that enhance corrosion resistance.
Regular maintenance, including fuel filter changes and periodic inspection for signs of corrosion, is essential for ensuring the longevity of your E85 fuel pump.
The market offers a range of fuel pumps suitable for high-horsepower E85 applications. Brands like Aeromotive, Walbro, and DeatschWerks are renowned for their E85-compatible pumps, offering various flow rates and configurations to meet diverse needs. When comparing options, consider not only flow rate but also factors like pump size, noise levels, and warranty coverage. Remember, investing in a high-quality, E85-specific fuel pump is crucial for ensuring reliable performance, preventing fuel system issues, and maximizing the potential of your 800 hp E85 setup.
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Fuel pump sizing for 800 hp E85 carbureted applications
E85's lower energy density compared to gasoline demands a fuel pump capable of delivering significantly more volume for the same power output. For an 800 hp carbureted application, this translates to a pump that can handle approximately 150-200 gallons per hour (GPH) at a minimum. This range accounts for factors like fuel pressure drop across the system, carburetor efficiency, and potential for future upgrades.
Analyzing Pump Specifications:
Don't be fooled by peak GPH ratings. Focus on the pump's continuous duty flow rate at your desired fuel pressure. A pump rated for 200 GPH at 40 psi might only deliver 150 GPH at 60 psi, which could be insufficient for your needs. Consider pumps with high-flow internal components and efficient brushless motors to ensure consistent performance under load.
Sizing for Safety and Performance:
Undersizing your fuel pump can lead to fuel starvation, lean conditions, and engine damage. Oversizing, while seemingly safer, can introduce unnecessary complexity and cost. Aim for a pump that provides a 10-20% buffer over your calculated fuel demand. This allows for headroom during hard acceleration, high-boost conditions, or future power increases.
Practical Considerations:
- Carburetor Type: Different carburetor designs have varying fuel requirements. Consult the manufacturer's recommendations for your specific carburetor.
- Fuel Pressure Regulator: Ensure your regulator can handle the flow rate and pressure requirements of your chosen pump.
- Plumbing and Filters: Use high-flow fuel lines and filters to minimize restrictions and ensure adequate fuel delivery.
Sizing a fuel pump for an 800 hp E85 carbureted application requires careful consideration of fuel demand, system pressure, and safety margins. By understanding the unique characteristics of E85 and following these guidelines, you can select a pump that delivers reliable performance and supports your engine's full potential.
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Top brands for E85 fuel pumps in high-performance builds
Achieving 800 hp on E85 demands a fuel pump capable of delivering massive volume reliably. E85's lower energy density compared to gasoline means you'll need a pump that can flow significantly more fuel to meet the engine's demands. This is where specialized high-performance fuel pumps come in, and several brands have established themselves as leaders in this niche.
Aeromotive stands out for its A1000 and A2000 series, which are staples in high-horsepower builds. These pumps are known for their robust construction and ability to handle the corrosive nature of ethanol. The A2000, in particular, can support upwards of 1,000 hp, making it a safe choice for 800 hp applications. Aeromotive also offers comprehensive fuel system kits, ensuring compatibility and ease of installation.
For those seeking cutting-edge technology, Radium Engineering offers the High Volume Fuel Pump Hanger paired with their Walbro F9000 pump. This setup is designed for in-tank use and provides exceptional flow rates while maintaining a compact footprint. Radium's focus on innovation and precision engineering makes their products a favorite among tuners pushing the limits of performance.
DeatschWerks is another top contender, with their DW65c and DW400 pumps being popular choices. The DW400, rated for up to 1,200 hp, is particularly well-suited for E85 applications due to its high flow capacity and durability. DeatschWerks also emphasizes plug-and-play compatibility, reducing the hassle of custom installations.
When selecting a brand, consider not just the pump's flow rate but also its compatibility with your fuel system and the manufacturer's reputation for reliability. Pairing the pump with a proper fuel pressure regulator and filtration system is crucial to ensure consistent performance and longevity. For 800 hp on E85, don’t skimp on quality—these brands have proven themselves in the most demanding applications.
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Installation tips for fuel pumps in 800 hp E85 carbs
E85’s lower energy density demands a fuel pump capable of delivering 30-40% more volume compared to gasoline setups. For an 800 hp application, this translates to a pump rated for at least 150-200 liters per hour (LPH) at 43 psi, depending on injector size and engine efficiency. High-flow, ethanol-compatible pumps from brands like Aeromotive, Walbro, or DeatschWerks are popular choices, often featuring dual or triple pump configurations for redundancy and consistent delivery under high-load conditions.
Before installation, verify the pump’s ethanol compatibility—E85’s corrosive nature requires materials like stainless steel, PTFE, or Viton to prevent degradation. Mount the pump securely, ideally in a submerged position within the fuel tank to prevent cavitation, which can starve the engine under hard acceleration. If using an in-line pump, ensure it’s positioned below the tank level and insulated from excessive heat sources. Pre-filter the fuel with a 10-micron filter to protect the pump and injectors from debris common in E85 blends.
Pressure regulation is critical for E85 setups due to its variable stoichiometric ratio (9.8:1 vs. 14.7:1 for gasoline). Use a high-pressure fuel pressure regulator (FPR) rated for E85, set to maintain 43-50 psi at the rail. Install a return-style fuel system to prevent pressure spikes and ensure consistent flow, especially during transient throttle conditions. Regularly monitor pressure with a gauge or data logger to catch fluctuations early, as E85’s hygroscopic nature can introduce air bubbles under low-pressure scenarios.
Post-installation, perform a leak test using a smoke machine or soapy water to identify cracks in lines or fittings. Prime the system before startup to purge air pockets, which can cause lean conditions and detonation. During break-in, monitor fuel temperatures—E85’s cooling effect can drop temperatures below optimal levels, necessitating a fuel heater in colder climates. Finally, log fuel pressure, air/fuel ratio, and injector duty cycle during tuning to ensure the pump is meeting the engine’s demands without overworking.
Upgrading to an 800 hp E85 setup isn’t just about the pump—it’s a holistic system requiring matched injectors, larger fuel lines, and a robust wiring harness. Oversize components by 20-30% to account for future power upgrades, and always consult a dyno tuner to calibrate the ECU for E85’s unique combustion properties. While the initial investment is higher, the pump’s reliability and the fuel’s cooling benefits make it a cornerstone of high-horsepower builds.
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Frequently asked questions
A high-flow, ethanol-compatible fuel pump with a minimum flow rate of 200+ LPH (liters per hour) is recommended to support the demands of an 800 hp E85 carb setup.
No, a standard fuel pump will not suffice. E85 requires a higher flow rate and ethanol-compatible materials to handle the increased fuel demand and corrosive properties of ethanol.
Brands like Aeromotive, Walbro, DeatschWerks, and Bosch are well-regarded for their high-performance, ethanol-compatible fuel pumps suitable for 800 hp E85 applications.
A dual fuel pump setup is often recommended for 800 hp E85 applications to ensure consistent fuel delivery under high-load conditions, though a single high-capacity pump may suffice if properly sized.
Look for fuel pumps specifically labeled as "E85 compatible" or "ethanol-friendly," ensuring they use materials like stainless steel, aluminum, or ethanol-resistant plastics to prevent corrosion and failure.
