Figuring that the whine was from the pump overheating, I thought I had the problem solved. But, while sitting still and doing a four-hour flush with Thermocure and varying the idle speed with the hand throttle now and then, at 3-1/2 hours the engine started to stumble. The fuel pressure was bouncing back and forth from 60psi to 20 psi. So, I shut it down. I felt the PVC tee enclosure and it was warm but not hot. I reached into the tee from the outside to feel the pump and burnt the hell out of my finger.
Sooo, the pump is generating its own heat and not getting it from the engine bay. But why? I then took a temp reading on my fuel tank and it was 130 deg F. Ah, Got it! These Walbro pumps pump way more volume than we need so more fuel gets returned than is used by the Sniper. It’s like a heating system. Fuel keeps circulating to the hot engine bay and close to the exhaust manifold then back to the tank so the tank and fuel will keep getting hotter and hotter. And finally, the pump starts cavatating and doesn’t get the cooling from the fuel, so it starts overheating.
My problem is probably amplified since I’m only ever traveling at a few MPH in the trails so I have less air movement about the engine bay and also around my tank. My tank is homemade aluminum and only 14 gal.
So, since the pump is the lowest GPM I can find that’ll do 60 PSI, I decided to try out an idea I found discussed on a Corvette forum where guys were trying to reduce excessive return flow. The solution was to wire a resistor in series with the pump to reduce voltage and consequently reduce flow along with reduced pump amperage. So, I got some resistors of various sizes and tried a 0.5 ohm first. I turned the key on for pre-start and I thought the pump wasn’t running right because it was much quieter than usual but the gauge popped right up to 60 PSI. So I started it and it fired right up as it usually does. Ran it for an hour in the yard and all seems good. The resistor was just dangling hooked up temporary and when I went to disconnect it I got more burnt fingers. (dummy). Then I read where it needs to be mounted to a metal base to carry off the heat. Since the 0.5 ohm seems to work fine, it’s now mounted to the fender well with some heat sink compound and a little make shift cooling fin on the opposite side. It doesn’t get so hot now.
I’m real pleased with this set up and can’t wait to get it back on the trail.