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Old 09-22-2022, 11:51 AM   #1
asthmamax11
 
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Auxiliary fuel system Does yours leak ?

Hello
Good morning

Who has had experience with the Auxilliary fuel system leaking ?

I hear it is fairly common

What was the remedy you implemented ?
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Old 09-22-2022, 12:30 PM   #2
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Are you referring to the DSX kit? I had a hell of a time when I first installed it leaking at the tank fitting. Just "working with it" and trying different combinations of tightness of the fitting helped... If mine ever shows any signs of leaking again, I'll either:
A) Go with an intank solution (expensive)
or
B) Try to use some kind of bulkhead type fitting that they normally use on fuel cells (cheaper), but not sure if the curved area of the tank where it's add will work.
or
C) Others have suggested going with the next size up fitting for the tank.

Honestly in hindsight tapping the tank was a stupid idea. I had expected more meat to thread things into.
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Old 09-22-2022, 12:38 PM   #3
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Quote:
Originally Posted by cjperformance View Post
Are you referring to the DSX kit? I had a hell of a time when I first installed it leaking at the tank fitting. Just "working with it" and trying different combinations of tightness of the fitting helped... If mine ever shows any signs of leaking again, I'll either:
A) Go with an intank solution (expensive)
or
B) Try to use some kind of bulkhead type fitting that they normally use on fuel cells (cheaper), but not sure if the curved area of the tank where it's add will work.
or
C) Others have suggested going with the next size up fitting for the tank.

Honestly in hindsight tapping the tank was a stupid idea. I had expected more meat to thread things into.
Thank you this is exactly the type of information I was looking for.

I just installed a few mods and got a bump in power.
Still on stock LT1 fueling
40k miles
Almost 20k boosted on Heartbeat kit pulley (single digit PSI)

I think it's time to be satisfied with my power levels and just enjoy the car.

In a few years I'll consider upgrading to a ZL1 or C7

Boost is most expensive when you get greedy
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Magnuson 2.3 Heartbeat
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Solo Performance Cat deletes and Axleback
Hurst short shifter
#'s coming soon

Riaction coilovers
1LE sway bars
BMR mm
BMR chassis brace

Flow one 19" wheels wrapped in Mickey Thompsons


02 Z28 M6 35th anniversary
80k miles
T-tops
Leather
Bolt ons
Joy to drive this classic every day!
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Old 09-22-2022, 04:54 PM   #4
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Someone here or on another thread today mentioned the danger associated with running less than 1/4 tank of fuel with DSX's low side fuel pump and Gen6's saddle style fuel tanks. I asked DSX about this and they said I shouldn't have a pressure problem unless the "low fuel light is on." Anyone know at what level the fuel light comes on?
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Old 09-22-2022, 05:14 PM   #5
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Quote:
Originally Posted by asthmamax11 View Post
Thank you this is exactly the type of information I was looking for.

I just installed a few mods and got a bump in power.
Still on stock LT1 fueling
40k miles
Almost 20k boosted on Heartbeat kit pulley (single digit PSI)

I think it's time to be satisfied with my power levels and just enjoy the car.

In a few years I'll consider upgrading to a ZL1 or C7

Boost is most expensive when you get greedy
I've had mine for almost 3yrs now and not a single leak.
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Old 09-22-2022, 05:31 PM   #6
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Quote:
Originally Posted by JSH View Post
Someone here or on another thread today mentioned the danger associated with running less than 1/4 tank of fuel with DSX's low side fuel pump and Gen6's saddle style fuel tanks. I asked DSX about this and they said I shouldn't have a pressure problem unless the "low fuel light is on." Anyone know at what level the fuel light comes on?
My fuel light pops on at 9% - roughly 2 gallons.

The biggest problem I see with tapping the tank is running the tap in too far. I used a 9/16 drill bit - a little smaller than recommended. I ran the tap in a little ways and checked it. Kept doing that until I got the right depth. Oh yeah, DO NOT USE A WRENCH ON THE FITTING!!
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Old 09-22-2022, 06:53 PM   #7
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Quote:
Originally Posted by MartinLe View Post
My fuel light pops on at 9% - roughly 2 gallons.

The biggest problem I see with tapping the tank is running the tap in too far. I used a 9/16 drill bit - a little smaller than recommended. I ran the tap in a little ways and checked it. Kept doing that until I got the right depth. Oh yeah, DO NOT USE A WRENCH ON THE FITTING!!
It sounds like a 1/4 tank is a good place to be at the strip.

We installed the DSX a year ago. When the car was on the lift a few weeks ago, we noticed the tap had been leaking, so we cleaned the outside and added some additional sealant. It's a real touchy little connection.
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HPE custom long block.
Edelbrock 2650 ported snout/inlet by KONG,
NW 103mm, 3"/9.18" pullies, DynoJet 965 whp / 870 tq.
NW 112mm, 2.75"/9.18" pullies, no dyno yet.
GT100/104, TOYO R888R
Denver 60 ft./1/4 mile/mph/DA (March 2023)
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Old 09-22-2022, 06:59 PM   #8
asthmamax11
 
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Quote:
Originally Posted by Puddin View Post
I've had mine for almost 3yrs now and not a single leak.
3 years
How many miles though ?
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Magnuson 2.3 Heartbeat
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Solo Performance Cat deletes and Axleback
Hurst short shifter
#'s coming soon

Riaction coilovers
1LE sway bars
BMR mm
BMR chassis brace

Flow one 19" wheels wrapped in Mickey Thompsons


02 Z28 M6 35th anniversary
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Leather
Bolt ons
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Old 09-22-2022, 07:15 PM   #9
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Quote:
Originally Posted by JSH View Post
It sounds like a 1/4 tank is a good place to be at the strip.

We installed the DSX a year ago. When the car was on the lift a few weeks ago, we noticed the tap had been leaking, so we cleaned the outside and added some additional sealant. It's a real touchy little connection.
I gave some thought to the possibility of it leaking. I figure that as long as the tap job is not too hacked up, there must be sealants out there that will stop the leak. Worst case scenario, the hole gets plugged with some sort of plastic welding material and the new hole gets tapped correctly.

Mine is solidly in place and I don't see why or how it would start leaking.
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Old 09-22-2022, 10:03 PM   #10
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Cordes performance aux setup I believe uses a bulk head fitting for that reason.
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Old 09-23-2022, 12:27 AM   #11
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Quote:
Originally Posted by asthmamax11 View Post
3 years
How many miles though ?
Was put on at a little past 10k and I'm now above 31 so 20k miles give or take.
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Old 09-23-2022, 12:34 AM   #12
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Quote:
Originally Posted by MartinLe View Post
I gave some thought to the possibility of it leaking. I figure that as long as the tap job is not too hacked up, there must be sealants out there that will stop the leak. Worst case scenario, the hole gets plugged with some sort of plastic welding material and the new hole gets tapped correctly.

Mine is solidly in place and I don't see why or how it would start leaking.

I have the same concerns... Makes me worried that a small fender bender could knock it loose? This may push me to do an in-tank pump for this reason.
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Old 09-23-2022, 03:07 AM   #13
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Quote:
Originally Posted by SOCAL.M6.ZLE View Post
I have the same concerns... Makes me worried that a small fender bender could knock it loose? This may push me to do an in-tank pump for this reason.
Agreed and did in-tank for this reason. Having a tapping in a tank that is too thin to be tapped properly AND below the fuel level is more than I was comfortable with.
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Old 09-23-2022, 09:11 AM   #14
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Quote:
Originally Posted by KingLT1 View Post
Cordes performance aux setup I believe uses a bulk head fitting for that reason.
I just contacted them about it, and, yes, they do sell one, thx
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OEM forged short block.
HPE custom long block.
Edelbrock 2650 ported snout/inlet by KONG,
NW 103mm, 3"/9.18" pullies, DynoJet 965 whp / 870 tq.
NW 112mm, 2.75"/9.18" pullies, no dyno yet.
GT100/104, TOYO R888R
Denver 60 ft./1/4 mile/mph/DA (March 2023)

Last edited by JSH; 09-23-2022 at 02:28 PM.
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