How to: DIY dual pump hanger...not for noobs
Im gonna keep this short and sweet. I didnt really decide to post this til i was almost complete with the hanger so ill try to quickly explain what i did. I am broke and i didnt feel like paying 300 bucks for the full blown hanger so here it is. If the post isnt complete just give me time because im fitting it in during work 
Parts needed
2 - 90 degree -6 an bulkhead fittings
-6 an line
2 fuel pumps (duhhh) I went with twin 355lph Aeromotive
an fittings to accomodate your fuel line setup
some solid and hollow square tubing from home depot( I think its 1/4 in. or so)
some small bolts and matching nuts ( no homo)
Must be able to weld...sorry noobs
Its almost woth buying the full blown hanger i.m.o. but when youve already spent a **** ton of cash on your build and you're straight sick of it, maybe you will be stubborn like me. This would be sooooo much easier if honda made the fuel tank hole even a half inch wider. Sadly, its retardedly small.
First thing you gotta do is obviously remove the tank and pump hanger assembly. Remove the pump and then cut off everything on the hanger assembly except the feed line bolt. Then drill 2 holes for the 6an bulkhead fittings. Make sure they are on the side of the hanger where they will not be in the way of the new pump hangers. Then cut 2 pieces of the hollow sqaure tubing about 1 1/4in long. Drill 2 holes through one side of the tubing the same size as the set screws. Bend the 2 pieces of solid tubing to match the stock bend on the hanger that was previously cut off. Drill 2 holes about 1/4 of the way through them. This will be where the set screws tighten and keep them secured . Proceed to weld nuts to the hollow bar so there is enough thread engagement for the set screws to tighten. I welded them with the screw threaded into the hollow bar a bit and then backed them out after i was done. This made sure the threads stayed in good shape. After that you can measure and weld them to the hanger plate with the bolt heads facing each other. Its tight this way but its the only way it will clear the hole on the tank. Use regular bolts not allen key like i did. It was a pain in the *** to tighten. This is when i took my first pics. You can see what im doing here.

The welds for the nuts were a pain in the *** cuz they are so small. If you have access to threaded rod and then cut it down it would work better.

This is basically what you will end up with. Minus the zip ties. They were there just for mock up until I got the hose clamp on. I also used 2 hose clamps on each pump before I installed it into the tank. The stock feed line will now be your return btw. I modded the feed line and hooked it up to the return line hardline. If you want to use the stock feed line as your return all the way to the bay thats fine too. Just depends on how you want it. Stock feed and return lines are the same exact size anyways on my DA so it really didn't matter. Also, dont forget to drill a hole for the wires. I used the smallest grommet possible and then sealed it with grey geaket sealer to be safe. Sorry i didn't take more pics I was just wrapped up into my work rather than documenting everything. If you are confused on how its mounted just take a look at the first 2 pics and you can figure it out. All in all it was a pain in the *** but at least I can say built not bought I suppose. Plus I get to keep another 300 dollars in my pocket
. Broke *** honda addict....OUT! P.S. If you don't like what I did just keep it to yourself and suck a D ya mudda s****.

Parts needed
2 - 90 degree -6 an bulkhead fittings
-6 an line
2 fuel pumps (duhhh) I went with twin 355lph Aeromotive
an fittings to accomodate your fuel line setup
some solid and hollow square tubing from home depot( I think its 1/4 in. or so)
some small bolts and matching nuts ( no homo)
Must be able to weld...sorry noobs

Its almost woth buying the full blown hanger i.m.o. but when youve already spent a **** ton of cash on your build and you're straight sick of it, maybe you will be stubborn like me. This would be sooooo much easier if honda made the fuel tank hole even a half inch wider. Sadly, its retardedly small.
First thing you gotta do is obviously remove the tank and pump hanger assembly. Remove the pump and then cut off everything on the hanger assembly except the feed line bolt. Then drill 2 holes for the 6an bulkhead fittings. Make sure they are on the side of the hanger where they will not be in the way of the new pump hangers. Then cut 2 pieces of the hollow sqaure tubing about 1 1/4in long. Drill 2 holes through one side of the tubing the same size as the set screws. Bend the 2 pieces of solid tubing to match the stock bend on the hanger that was previously cut off. Drill 2 holes about 1/4 of the way through them. This will be where the set screws tighten and keep them secured . Proceed to weld nuts to the hollow bar so there is enough thread engagement for the set screws to tighten. I welded them with the screw threaded into the hollow bar a bit and then backed them out after i was done. This made sure the threads stayed in good shape. After that you can measure and weld them to the hanger plate with the bolt heads facing each other. Its tight this way but its the only way it will clear the hole on the tank. Use regular bolts not allen key like i did. It was a pain in the *** to tighten. This is when i took my first pics. You can see what im doing here.

The welds for the nuts were a pain in the *** cuz they are so small. If you have access to threaded rod and then cut it down it would work better.

This is basically what you will end up with. Minus the zip ties. They were there just for mock up until I got the hose clamp on. I also used 2 hose clamps on each pump before I installed it into the tank. The stock feed line will now be your return btw. I modded the feed line and hooked it up to the return line hardline. If you want to use the stock feed line as your return all the way to the bay thats fine too. Just depends on how you want it. Stock feed and return lines are the same exact size anyways on my DA so it really didn't matter. Also, dont forget to drill a hole for the wires. I used the smallest grommet possible and then sealed it with grey geaket sealer to be safe. Sorry i didn't take more pics I was just wrapped up into my work rather than documenting everything. If you are confused on how its mounted just take a look at the first 2 pics and you can figure it out. All in all it was a pain in the *** but at least I can say built not bought I suppose. Plus I get to keep another 300 dollars in my pocket
. Broke *** honda addict....OUT! P.S. If you don't like what I did just keep it to yourself and suck a D ya mudda s****.
Last edited by b20ricepower; Aug 17, 2012 at 11:11 PM.
Thread
Thread Starter
Forum
Replies
Last Post
danedoremus
Welding / Fabrication
21
Nov 7, 2011 11:58 AM
MarkosMotorsports
Road Racing / Autocross & Time Attack
4
May 24, 2004 06:58 PM



