How to convert an S10 fuel pump to run with an LS engine

I have found a lot of info about converting factory S10 fuel pumps to work with LS engines.  There are some ideas I agree with and some I don't.  This is what I came up with for my build.

The 2003 S10 V6 fuel pump module is a Delphi unit (part number FG0123).  The module consists of a pump that sits inside of a bucket.  The bucket is constantly refreshed with fuel from the tank and provides a means to maintain a fuel supply when there is low fuel and hard cornering/acceleration/deceleration is taking place.

FG0123 - Note, I have it already apart and have attached the Racetronix wiring.  This was a mistake.   I will explain later.

The two fuel pumps.  Racetronix FPA-001B on the left, factory pump on the right (you can easily see the two inlets on the factory pump)

The FG0123 is an upgrade from prior versions and has a very nice way of keeping the bucket full. The pump has dual inlets and dual outlets.  One inlet pulls from the tank, the other from the bucket.  One outlet fills the bucket and the other outlet feeds the engine.  The bad part is that the fuel pump only pumps about 90 liters/hr.  This is well short of the 255 liters/hr that a Walbro or Racetronix pump flows and what a high-horsepower LS engine requires.

FG0123 base - Notice the two inlets.

I did a little research and determined I needed the Racetronix FPA-001B pump.  This pump is an upgrade for LS1-powered Camaros and Firebirds.  Apparently, I did not do enough research.  This pump will not work in my module.  Not even close.

I contacted Racetronix and mentioned my dilemma.  They basically stated that I need to find another module.  After much more research, I bought a module from eBay for a 2002 Z28.  I get it and immediately notice how short it is.  It is a good 2 inches shorter than the S10 module.  Plus, the connector for the wiring harness is different.  Damn.

I decided to bastardize it and make it work.  A hybrid approach, so to speak.  I decided I was going to use my S10 module top and the LS1 Camaro base.  So I got to work on Frankenpump.

One thing I want to insert here:  I have seen some posts where people cut a hole in the bucket and just make sure they have a 1/2 tank or more of fuel.  My personal opinion is that the bucket is there for a reason, use it.

The first thing I did was to cut the flaring off at the base of my S10 module (FG0123) and the Camaro module.  The S10 module has its springs in the base.  The Camaro module has its springs between the base and the top.  I could not use the S10 springs.  I could not use the Camaro springs individually since they would be too short.  I decided to double-up the springs and put them on one side.

Flaring on the FG0123 tubes.

No more flaring.

I used a flaring tool to re-flare the ends of the pipes used to hold the base to the top.  The pipes are a very hard steel and it will be very difficult to reflare.  Have patience, it will happen.

I then was able to follow the instructions for the Racetronix pump to be put in to the Camaro base.  All went well until I went to connect the fuel tube that runs from the pump to the top of the module.  It was too short (not surprisingly since it was designed for a Camaro module, not Frankenpump).  I ordered a new 233mm hose from http://autoperformanceengineering.com/html/kits.html.  Note: this hose was a huge pain in the ass to connect to the nipple at the top of the module.  Be prepared to spend some time and harsh language is a must.  

Frankenpump module with the Camaro base and S10 top.  Notice the double springs on one arm.  That black hose took way too long to put on.

After getting that on, I figured I should check the length of the wiring harness.  Same issue, too short.  I decided to use the fuel pump connector on the Racetronix harness with my original wires.  I ended up ordering some terminals from Amazon that matched perfectly (I needed to have the tab on them.  I don't want a terminal sliding out of my fuel pump connector), but took 3 weeks to get here.

New terminals

The terminals showed up and I modified my S10 harness to connect to the Racetronix connector.

Modified S10 harness

Completed Harness

Once that was done I was able to complete the instructions in the Racetronix kit and finish the pump.

Done.

Now to test.  The tank is out of the truck, so I am going to wait until I get the frame back from the powder coating place (that is another story) and mount it before I put fuel in it and test.  Will edit this post when I am done.

Edit: 2/6/2016: The pump works flawlessly at this point.  Truck is going on the dyno this week and we will verify all is well.