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Old 05-01-2019, 12:15 PM
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Modifying stock sending unit

Anyone have experience with modifying a stock 90's sending unit for a larger return line and electrical bulkhead? I recently put an aeromotive stealth 340 in my 93 C1500; however, the pump pulls enough amps that is has now melted the stock electrical bulkhead. I bought a bulkhead for the 99+ GM trucks that is rated at 30 amps; however, my stock sending unit won't accommodate the larger bulkhead without major rework. Figured I would go ahead and increase the return line size since I'm going to have to rework the sending unit. Thanks in advance!
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Old 05-01-2019, 01:00 PM
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Are you asking about a mechanical/physical modification or an electrical one?
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Old 05-01-2019, 03:52 PM
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The electrical. The fuel return is easy enough once I figure out how to shoehorn the bigger electrical bulkhead in.
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Old 05-02-2019, 05:37 AM
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Can you buy a new plug connector and wire it in? Or the junk yard if needed. Better than trying to put a square peg in a round hole.
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Old 05-02-2019, 10:17 AM
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I did buy a higher amp rated connector. I included pictures to the original post. At this point, I am going to fab a completely new top plate so I can control placement of the feed, return, vent, and overflow.
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Old 05-02-2019, 02:13 PM
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Fuel pump

This seems to be an ongoing battle, finding a pump and electrical connector to match. I went to the local auto repair shop and got a take out fuel pump with the connectors I needed and built my own pump from there. This is my spare pump and has a genuine Walbro 255. Beware of the off shore knockoffs, they will not last.
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Old 05-02-2019, 06:10 PM
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something like this for the electrical?...http://www.revolutionelectronics.com..._Isolator.html
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Old 05-03-2019, 10:55 AM
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I've got the aeromotive stealth 340. Pump is amazing, was hoping my PWM controller would allow me to get away with the stock metripack 150 connector.


Spoiler alert: it didn't
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