And data analysis since I think stuff through the best by typing it out.
I pressure tapped a bunch of places with the 2 pumps running.
With 58 rail pressure I see 60 at the tank with the -8 feed. That's pretty dang good! I need to re run my calculations and see if my coefficient of friction value matches the single pump -6 case.
The bad part? The pressure on the return is a LOT. I am using the stock carb steel feed line from the firewall back to the tank.
32 psi at the regulator. Ish.
And to narrow down, is it the section of line between the regulator and the line near the tank, is it between the tank and there, I tapped right where there is a rubber junction on the stock steel feed line to the tank return
22 psi.
So I have 10psi of restriction through the first 80% of the line and the flex fuel sensor
and 22 psi of restriction in the last 20% of the return. I think a lot of that probably lies in the return tube that is soldered into the fuel pump hanger. I can't really go any larger because the hat runs out of room for another (or one bigger) return.
I could replace the section of line between the flex content sensor and the tank with 3/8" AN and loose maybe 8 psi restriction which would be helpful, but not as much as I want.
The other dilemma is the FPR is not lowering fuel pressure at idle. Potentially overloading the regulator with flow, possibly there is too much backpressure on the system. Probably the later.
So the solution (as mentioned) is to switch the second pump on with boost. I don't have a switch on hand and since I need to leave home to race Friday, I don't have time to set it up. I think I am going to just pull the fuse on the second pump to drive the 3 hours back to Dad's and when we head to the track I will pop the second fuse back in at the track.
I (slightly) don't like the idea of switching the pump on because if the switch fails I can lean out and kaboom, but all that additional fuel load is a lot of amps, I'm sure added heat to the fuel, and going to cause issues with getting the fuel system return line sized correctly.
But enough of so-so news, the good news, the dual pumps supply the fuel flow the engine demands.
Base pressure is 57/58ish and I am getting 65 psi under 10psi of boost, so 7-8 psi of pressure rise for 10 psi is close enough.
I also am 5-10% rich in the boost range so I need to pull fuel out. That makes sense because the injectors are seeing 65 psi instead of 45 psi.
I need to pack my tools tomorrow and do a pull with some fuel pulled. If everything looks good fingers crossed it runs good Saturday and everything stays together. Rain looks like a non issue.