fuel tank bulkhead connectors.

[ericjon262]

as you may know I've been hunting for a solution to the tiny pins in the fuel tank bulkhead connector.



so far, I've machined some UHMW plastic to pass through the wires, I don't really like this because it doesn't actually seal.

I found this:

http://www.radiumauto.com/Bulkhead-Fuel ... -P682.aspx

but it's way to tall to fit in the tunnel...

Does anyone have part numbers for comparable Amphenol connector with a right angle top? it only needs to have 2 wires, although 3 would be preferred. I've been digging through Mousers parametric search with minimal luck.

and for the "it's fine put it together" crowd, this is out of a buddies car with a 255 LPH pump, I'm not a fan of toasted wires in a fuel tank, he was lucky it just blew the fuse.

[ericjon262]

I was directed to this by a guy on GRM, while the terminals don't appear to be larger, there are more available to transmit power, so I can run power through two or more terminals. it also uses larger wire, which increases the capacity of an individual terminal by allowing the wire to act as a heat sink for the terminal. I think it will work, but I will need to figure out a hold down, should be a cake walk.

https://www.racetronix.biz/p/universal- ... y/bcws-001

[Emc209i]

Post results. This is also on my to do.

[pmbrunelle]

If you want to use all four pins of the Racetronix connector for the fuel pump, I would suggest locating the splice points (where the single feed/ground wire splits into 2x 14 AWG) as far away as possible from the connector (like 2+ feet distance).

From the splice point, the 14 AWG wires should have equal lengths until the Racetronix connector. The idea is to have sufficient (and equal) resistance in each branch, to promote 50-50 load sharing between both contacts. We don't really know how well the contact resistance will be matched between contacts, so it is wise to implement some external ballast.

********************************************************************************

I like these parts-sourcing challenges.

How about this?
http://www.radiumauto.com/Electrical-Bu ... P1049.aspx

You might need to braze washers onto the sending unit top to meet the panel thickness requirement.

[The Dark Side of Will]

as you may know I've been hunting for a solution to the tiny pins in the fuel tank bulkhead connector.



Does anyone have part numbers for comparable Amphenol connector with a right angle top? it only needs to have 2 wires, although 3 would be preferred. I've been digging through Mousers parametric search with minimal luck.

It looks like the in-tank connector has 4 cavities... is that accurate or am I confusing the terminal tool access for terminal cavities?

Maybe there's a 4 wire substitute for the top piece only?

[Honest Don]

I was looking at these:

https://www.ebay.com/itm/381011744617



That racetronix setup is pretty slick if it directly replaces the GM piece.

[ericjon262]

Post results. This is also on my to do.

Will do. The part should be here later today, I'll take detailed pictures comparing it to stock parts.

If you want to use all four pins of the Racetronix connector for the fuel pump, I would suggest locating the splice points (where the single feed/ground wire splits into 2x 14 AWG) as far away as possible from the connector (like 2+ feet distance).

From the splice point, the 14 AWG wires should have equal lengths until the Racetronix connector. The idea is to have sufficient (and equal) resistance in each branch, to promote 50-50 load sharing between both contacts. We don't really know how well the contact resistance will be matched between contacts, so it is wise to implement some external ballast.

********************************************************************************

I like these parts-sourcing challenges.

How about this?
http://www.radiumauto.com/Electrical-Bu ... P1049.aspx

You might need to braze washers onto the sending unit top to meet the panel thickness requirement.

those may work, as you mentioned though, they will require something to take up the additional thickness.

Thats a good idea for the parallel branches, I'm not sure the the load share needs to be exactly 50/50, but it wouldn't be much good if it's 20/80 or worse.

It looks like the in-tank connector has 4 cavities... is that accurate or am I confusing the terminal tool access for terminal cavities?

Maybe there's a 4 wire substitute for the top piece only?

like this?

https://www.racetronix.biz/p/fs-bulkhea ... way/bca-4w

also

https://www.racetronix.biz/p/connector- ... de/rcs-061

also

https://www.racetronix.biz/p/connector- ... wa/rcs-058

I really don't like the pull to seat connectors, if I was more patient, I would order some GT 150.2 connectors to replace the metri-pacs

originally, I was going to order individual parts, but I started thinking that by the time I source comparable wire, and make it, it was worth the extra $35 to get the kit.

I was looking at these:

https://www.ebay.com/itm/381011744617



That racetronix setup is pretty slick if it directly replaces the GM piece.

I have the same part, or something very similar, on my current tank. I'm not too wild about it, it doesn't look like it seals as well as I would hope, the Racetronix part is an actual GM part, I have 99% confidence that it will be a drop in replacement, and because it's an OEM part, it met some kind of endurance/safety rating at one point. it's also much lower profile than the "seal" you linked to.

[The Dark Side of Will]

It looks like the in-tank connector has 4 cavities... is that accurate or am I confusing the terminal tool access for terminal cavities?

Maybe there's a 4 wire substitute for the top piece only?

like this?

https://www.racetronix.biz/p/fs-bulkhea ... way/bca-4w

also

https://www.racetronix.biz/p/connector- ... de/rcs-061

also

https://www.racetronix.biz/p/connector- ... wa/rcs-058

I really don't like the pull to seat connectors, if I was more patient, I would order some GT 150.2 connectors to replace the metri-pacs

Yeah, that was what I was asking about... looks like the in-tank connector is the same (similar? compatible?) connector the Fiero tank has stock, which is cool.

[ericjon262]

sorry, I didn't answer that part, yes, the stock in tank connector has 4 positions as well, but only 2 are used. I would bet the above linked part is a direct replacement.

[The Dark Side of Will]

sorry, I didn't answer that part, yes, the stock in tank connector has 4 positions as well, but only 2 are used. I would bet the above linked part is a direct replacement.

Probably form/fit/function replacement... you mention pull-to-seat pins. I don't think those existed in the '80's.

[The Dark Side of Will]

I really don't like the pull to seat connectors, if I was more patient, I would order some GT 150.2 connectors to replace the metri-pacs

Replace which Metri-Packs? The external tank connector *looks like* a Metri-Pack to me.

[ericjon262]

Probably form/fit/function replacement... you mention pull-to-seat pins. I don't think those existed in the '80's.

They were being phased in during the late 80's. IAC's, TPS's, and CTS's were the first parts I am aware of to use them, this particular connector is for an F body fuel tank, not sure of the year, but I would guess in the 90-97 range

Replace which Metri-Packs? The external tank connector *looks like* a Metri-Pack to me.

the male connector (which has female pins), some delphi GT connectors were designed to be replacements for Metri-pac pull to seat connectors.

https://www.bmotorsports.com/shop/produ ... cts_id/799

https://www.bmotorsports.com/shop/produ ... cts_id/835

That being said, I have not investigated the current capacity of these connectors.

[pmbrunelle]

the male connector (which has female pins), some delphi GT connectors were designed to be replacements for Metri-pac pull to seat connectors.

That's a good tip, I didn't know about that.

Among the other Metri-Pack 150.2 pull-to-seat connectors found in the Fiero, the V6 ignition module uses the 150.2.

The snap clip on its connector broke off (old brittle plastic), so I cut the wires shorter to put on another Metri-Pack 150.2 pull-to-seat.

I thought to myself, this isn't so good if every time I service the connector the wires get shorter. I don't leave service loops in my car like I do on my house.

That being said, I have not investigated the current capacity of these connectors.

Current capacity roughly goes with the width of the blade.

Do you have the Delphi/Aptiv pdf catalog? Current ratings can be found in the catalog.

[ericjon262]

the male connector (which has female pins), some delphi GT connectors were designed to be replacements for Metri-pac pull to seat connectors.

That's a good tip, I didn't know about that.

Among the other Metri-Pack 150.2 pull-to-seat connectors found in the Fiero, the V6 ignition module uses the 150.2.

The snap clip on its connector broke off (old brittle plastic), so I cut the wires shorter to put on another Metri-Pack 150.2 pull-to-seat.

I thought to myself, this isn't so good if every time I service the connector the wires get shorter. I don't leave service loops in my car like I do on my house.

That being said, I have not investigated the current capacity of these connectors.

Current capacity roughly goes with the width of the blade.

Do you have the Delphi/Aptiv pdf catalog? Current ratings can be found in the catalog.

Glad I could provide a useful tidbit. both the metri-pack 150, and GT 150 connectors use 1.5mm blade widths, so I imagine the capacities are comparable. I don't have a catalog.

+++++++++++++++++++++++++++++++

photo dump in progress.

unpacking:





an assortment of shinkboot, some silicone grease, and a bit of solder is included.



for some reason, they couldn't provide the same color wires inside and outside of the tank, but there's only one thats different (purple vs gray)



the wire itself appears to be high quality.



the connector





it's worth noting that the internal plug can be inverted be careful to make sure your wire designations are what you think they are. the lock plate can be installed either way as well.





the part has an inspection sticker on it, with clearly legible data.





I haven't got around to doing anything with it yet other than pictures, I'll provide further information when I get it put together. FWIW, if you have an earlier car, this is what the tank connector looks like, I suspect it has a higher capacity than the later connector.

[pmbrunelle]

I don't have a catalog.

Download this:
https://www.powerandsignal.com/docs/DCS ... atalog.pdf

I found the GT pull-to-seat replacements on page 22 of the pdf.

[ericjon262]

Browsing ballenger motorsports for some relays, I saw this:

https://www.bmotorsports.com/shop/produ ... ts_id/5098

https://www.bmotorsports.com/shop/produ ... 7B50%7D248

https://www.bmotorsports.com/shop/produ ... ts_id/5163

The terminals in the kit are about 3x larger than the racetronix part with a total of 6 positions! I'm ordering one and if it fits on the sender, may use it instead of the racetronix part.

[Shaun41178(2)]

Damn dude. You need this more than bulkhead connectors

[ericjon262]

Damn dude. You need this more than bulkhead connectors

Dirty hands, clean money.

[Shaun41178(2)]

https://youtu.be/5IOXzpRJ714

You watched me wash em

[ericjon262]

I guess it's easy enough to see when Shaun is bored.