I appreciate all the help on the fuel delivery so far using that and what I have researched I have come up with a first draft. First I want to share some background.
I bought this rig to use as a trail rig not so much a rock crawler but I would like to be able to tackle some mid level technical trails with it, explore some of the high trail passes in the Southern Colorado area and explore some Moab trails. So I expect to drive on some long trails with significant grade and potentially tackle some steep obstacles at varying elevations.
The tank for the 45 is custom made and sits above the frame rails under the bed. In order to access it, it appears you have to lift the bed off, so making a trail repair to anything in the tank could be problematic. I have read that intake pump set ups are better for the pump for cooling and longevity, so I would prefer a submerged pump but not in the main tank because of access.
Considering use and maintenance I am looking to go with a surge tank that uses a submerged pump in the tank. After a lot of searching and comparing I have tentatively settled on using the Fitech Command Center 2 #40004. It is a surge tank with a submerged HP pump and a fuel regulator built into it. The biggest concern I have with it is the combining of the low pressure return lines back to the main tank. Does anyone see an issue with this in my diagram?
Edit question: Since I will be using a regulator, can I "deahead" the system at the fuel rail and just not run a return line from it? My research has not turned up a good answer. I would still run a return line from the surge tank.
Edit: Fitech also sells a single pump surge tank that would allow the fuel line return to run back into the surge tank rather than sending back to the main tank. It does not have the fuel regulator attached so I would have to plumb that in separate. Hyper fuel single pump g-surge tank #40007
I am also planning, as suggested, to use the mechanical pump on the engine to run the low pressure feed line to the Command Center (surge tank.) I like this idea because it is already there, they are generally reliable, easy to replace, and don't have the overheating possibilities as external electric pumps.
The system would run like this:
LP feed line from main tank to mechanical pump with inline filter
LP feed from mechanical pump to surge tank
HP feed line from surge tank to fuel rails through HP filter, surge tank uses a built in fuel regulator
LP return Line from surge tank to main tank
LP return from fuel rail ties into LP line from surge tank to main tank
Picture to illustrate
View attachment 1736471