Bob...  don't do it.

It is so easy to return the fuel to one of the main tanks, it just cant be worth the hasstle and risk.

I return the fuel to my left tank (like Tracy).  But instead of a pump for transfer I just installed the stock fuel selector.  When running off the right tank it effectively transfers the fuel to the left.  I set a simple timer (on my engine monitor) to remind me to switch back.

Very simple, easy to install, no extra pump or wiring, no risk of heating the fuel even on the hottest days and highest altitudes, system work the way it was designed, parts readily available.

I just can't see any advantage of a returnless system.

Dave Leonard

 

Todd,

I'm going to build a returnless system based on your design.  I found this fuel cooler at Jeg's for about $40.  Jeg's P/N 771-1009.  The finned area is 4.5 X 5 X 7/8 (inch), which I think is a little bigger than the one you made.

http://www.jegs.com/cgi-bin/ncommerce3/ProductDisplay?prrfnbr=3532&prmenbr=361

I'm sure it's nicer looking than anything I could build myself.  I'll post pictures of my alternator bracket one of these days to prove it.

Bob White

-- http://www.bob-white.com
N93BD - Rotary Powered BD-4 (real soon)