When it comes to building a high-performance vehicle, a stout fuel system is paramount. Without a reliable supply of atomized fuel, even the most powerful engine will fall flat. For our Project ODB, a 1996 Caprice sporting a potent LS swap, we knew a factory fuel system wouldn’t cut it. We teamed up with the experts at DeatschWerks to design and install a complete fuel system capable of supporting our power goals and beyond.
The Heart of the System
Our journey began with the heart of the system: the fuel pump. Fortunately, Project ODB already sported a DeatschWerks DW400 pump, installed after the factory unit met its demise. However, we were curious to know more about the DW400’s capabilities. James Elkins at DeatschWerks filled us in. “The DW400 can safely support up to 900 horsepower naturally aspirated on 93 octane pump gas,” he explained. “On ethanol, that number drops to 650 horsepower.” For those planning to spray some nitrous, the pump can handle a staggering 1,000 horsepower on 93 octane – 800 horsepower from the motor and an additional 200 horsepower from the juice. Boosted enthusiasts will be happy to know the pump supports up to 800 horsepower on 93 octane with up to 20 PSI of boost.
The fuel system parts are laid out (note our 100 horsepower adding sticker).
Armed with this knowledge, our focus shifted to the fuel lines, the fittings, the filter, and the regulator. DeatschWerks offers a vast array of AN fittings in various sizes and angles, ensuring a clean, custom installation. We opted for -8AN for the supply line and -6AN for the return. The real beauty of an AN-plumbed system lies in its versatility. With a selection of straight, 45-degree, 90-degree, 120-degree, and 180-degree fittings, routing the lines is a breeze. Add in the ability to cut the nylon-braided PTFE hoses to length, and the possibilities are endless. DeatschWerks’ fittings are manufactured to applicable JIC and SAE standards, constructed from heat-treated 6061 aluminum, and anodized in a titanium or matte black finish.
The change to AN fittings will save time dealing with those pesky hose clamps.
Mounting the Components and Plumbing the System
We began at the rear of the car, working forward to minimize mess and complication. The factory hard lines were quickly abandoned in favor of our new AN setup. A snapped factory line, impossible to repair, further justified the upgrade. With the old lines drained and removed, attention turned to mounting the vital components.
Out with the old and broken fuel system.
The DeatschWerks DWFF100 in-line fuel filter kit, featuring a -8AN flare inlet and outlet type made from T6061 aluminum, is designed to ensure optimal fuel purity and performance. With a 40-micron rating, it effectively filters out contaminants, while the external material, a 35mm neodymium ring, provides robust construction. The kit employs a dual filtration system: magnetic filtration using a 304 stainless steel mesh and mechanical filtration capable of handling over 1,000 LPH. This setup guarantees thorough fuel cleansing, protecting your engine from debris and impurities. The DWFF100 is anodized in a titanium or matte black finish and is fully compatible with ethanol and methanol.
The DeatschWerks DWFF100 fuel filter was securely fastened to the Caprice's frame, ensuring clean fuel reaches the engine.
Nearby, the fuel pressure regulator was mounted to the passenger-side frame rail.
While the regulator came with a gauge, we relied on the pressure reading from our Edelbrock Pro Flow 4+ to monitor the system. The DWR1000 AFPR+ regulator is rated for 1,000 hp and features precision adjustment from 30 – 100 PSI with two psi-per-turn ball-bearing adjustments. Its 45 mm nitrile diaphragm maintains exceptional set pressure accuracy. The regulator is constructed from heat-treated 6061 aluminum, anodized in a titanium or matte black finish, and is fully compatible with ethanol and methanol.
Running AN lines allows for a perfect connection to our Edelbrock Pro-Flo System.
With components in place, the hoses were cut to length and the AN fittings were carefully assembled. The supply and return lines were routed along the driver-side frame, keeping them a safe distance from the heat of the exhaust system. Insulating the lines further protects against heat soak.
DeatschWerks offers their nylon hose in -6AN, -8AN, and -10AN sizes, with lengths of 3, 6, 10, and 20-foot options. The hose is available with CPE and PTFE liners and is burst-tested to 1,000 PSI. The CPE hose is compatible with E85, while the PTFE hose is for use with E100 and methanol and offers zero vapor permeability. The black nylon hose is stainless steel cord-reinforced, while the stainless steel hose is often required by race-sanctioning bodies for use where exposed due to its abrasion resistance.
A Fuel System Fit for a Beast
The result is a fuel system that not only looks incredible but provides the capacity for serious performance. According to DeatschWerks, this setup is good for 600+ horsepower. With our power goals well beyond that, we’re confident this system will support our ambitions. The experts at DeatschWerks have been invaluable in the design and implementation of this fuel system. Their wealth of knowledge and top-tier components have given us the foundation for making big power with Project ODB.
Project ODB now has room to grow into its fuel system’s capabilities.
As we continue to push the limits of our LS-swapped Caprice, the DeatschWerks fuel system will be ready. With its immense flow capacity and custom, AN-plumbed design, this setup ensures our engine will never go thirsty. Whether on the street or at the track, Project ODB is primed for performance. The fuel system is just the beginning. Stay tuned as we continue to modify and refine our ’91 Caprice, transforming it into a true sleeper.
DeatschWerks: Fueling Your Performance Ambitions
The world of high-performance fuel systems is complex, with many options available. DeatschWerks sets itself apart with not only exceptional components but the expertise to back them up. From pump selection to plumbing design, their team is dedicated to helping enthusiasts build the fuel system their vehicle demands. With Project ODB, we’ve experienced this firsthand. The result is a bulletproof fuel system, ready to feed our power-hungry LS engine.
Whether you’re building a 1,000-horsepower monster or a 500-horsepower weekend warrior, DeatschWerks has the components and knowledge to ensure your fuel system is up to the task. Their DW400 pump, like the one in our Caprice, is a proven performer. Paired with their vast selection of AN fittings and PTFE hoses, custom plumbing is a breeze. Add in their fuel filters, regulators, and new LS injector swap kit, and DeatschWerks is a one-stop shop for all your fueling needs.
Putting it to the Test
As we move forward with Project ODB, the DeatschWerks fuel system will be put to the test. With its immense capacity and custom design, we have no doubts it will support our power goals. The experts at DeatschWerks have been invaluable in this build, providing the components and expertise needed to create a truly bulletproof fuel system. As we continue to modify and refine our Caprice, their support will be crucial. With a stout fuel system in place, the sky’s the limit for Project ODB.
The Journey to Building a Beast
The journey to build a high-performance vehicle is rarely easy. With the guidance of companies like DeatschWerks, the process becomes much less daunting. Their commitment to providing top-tier components and exceptional expertise makes building a car like Project ODB possible. As we continue to push the limits of our LS-swapped Caprice, the DeatschWerks fuel system will be the backbone of the build, ensuring our engine never goes thirsty. The world of high-performance cars is an exciting one, and with DeatschWerks behind us, we can’t wait to see where the journey takes Project ODB.
