I'm wanting to redo the fuel system on my '83 F250 with Cummins. Right now it is only using one of it's two 19 gallon tanks, the front tank. I'd like to replace the rear tank with a drop in replacement 38 gallon; and, would it be worth while to add a sump to the new 38 gallon tank?

Picture of a 38 gallon installed

I was thinking of adding a typical billiet $$$$ diesel sump to the lowest point in the tank pictured or using a formed steel sump more common in drag racing applications.

http://www.jegs.com/i/Jegster/550/40793/10002/-1?parentProductId=747210

My second question is which lift pump should I be looking at? I never plan on making big power, replace the stock turbo, the only thing I might do at a later point is add RV275 injectors and possibly a tuner. Stick with a FASS or AirDog? Build a system from scratch?

And last, I'd like to turn the the forward 19 gallon tank into an auxiliary tank that I could pump into the main 38 gallon tank. Would this be as simple a wiring a pump and plumbing into the return line?

Bump

Given the types of fuel pumps that are available to the diesel market I don't think your going to see any real benefits of running a sump in your tank. Unless your going for that unique factor, just get a good quality after market fuel pump, mount it on the frame, and enjoy it. Pumps like the AD 100 or 150 or similar FASS pumps will provide more fuel than your engine will ever be able to handle

I agree Diesel4life, but it seems that AD has been having a lot of problems with their pumps lately. AD says they have addressed the issues and fixed the problems. It seems there are still some of the older pumps on dealer shelves that might still have the problems though. I am not trying to beat AD up because I have had one for over 2 years with zero issues and am quite happy with it. Just something to be aware of.

It's mostly the high pressure applications like mine that have been seeing issues, and if you do buy one of the old stock that's been sitting in the warehouse they'll send you a replacement pump unit in a hurry no charge.

The The ones I read about lately have been Raptors, 100's and 150's. What kind of high pressure application are you speaking of?

My DF-165 is in a super-doody 7.3, which I run at 62 psi. under 55 psi and my mileage goes all to hell, hard on injectors as well.I haven't played with the raptors, although it is the same pump as the full system, just with threaded ports instead of o-ring ports.

The pumps I am speaking of have all been on Dodge 24v cummins. standard pressures like mine. dont get me wrong I have had an ADII 165 for 2 years with no problems, but it seems there are many folks just like me that are,but with newer manufacture dates. I am not trying to preach against AD's product, but anyone buying one needs to be aware there are problem before laying out $500+.

The pumps I am speaking of have all been on Dodge 24v cummins. standard pressures like mine. dont get me wrong I have had an ADII 165 for 2 years with no problems, but it seems there are many folks just like me that are,but with newer manufacture dates. I am not trying to preach against AD's product, but anyone buying one needs to be aware there are problem before laying out $500+.

I Hear you, in the future though no matter what my project is I'll be running either a waterman, belt drive, or fuellab electric pump. Fass and Airdog have both been having their issues lately that are supposed to be solved, I'm sorely tempted to replace mine and it's less than a year old.

I added a sump to a buddy's build similar to what you suggested. It was rather costly as the kit was around $200.00 but he swears by it and regularly runs it down to bone dry. If you have the money, id do it.

On a Dodge pickup fuel tanks I would be scared to death to do a sump on a truck that is used offroad. First time I go over that rock, log or stump and hook it I will be walking home 40 miles out of the woods.I can see doing it for racing applications... But there is a reason why fuel tanks are pulled from the top.

that's exactly the reason I haven't done a sump yet, although FASS has a top draw sump setup http://www.fassride.com/shop/accessories/fuel-sump-kits.php if that sump is shallow enough it might fit with the skidplate still in place. at least it might with my ford, I can't recall how much space my Dodge had.