I wouldn't return just to the filler, tho, have the tube extend inside the filler down to near the bottom of the tank.

 

I agree with Ross, if you return to a tube installed in the filler neck run it down into the tank, but not too close to the bottom or directed at the pickup so it doesn't foam the fuel in the tank. gas conducts heat better than water so you don't need a lot of flow. It the stopping of the flow by the carb float causing back pressure that causes the pump to heat up, it's basically trying to push fuel thru a plugged line. think about what it might be like to be blowing liquid or even air thru an open hose then have someone suddenly repeatedly plug and release the end of the line while you keep blowing with the same effort.

 

An old main jet is the perfect orifice, and obviously adjustable (by replacing with a different size), if you can figure out how to incorporate one in the return line. I know guys on the HAMB have done just that, but usually that requires machining a custom fitting. The restrictor for a bypass oil filter, on the other hand, is a simple .060" orifice built into a pipe fitting, NPT threaded:
Orifice / restrictor fitting

BTW, you don't want too small a flow in the return, or it will just vaporize on its way to the tank.

 

Yes, a soft steady stream would be about ideal kinda like it's p*$$ing back into the tank.

 

HA,HA,HE,HE got the picture AX. All depends how old one is.....as to how much flow there is....... I will try to get more pics for you as I complete the steps to try and get this done.

Had some honey do's today so I could not touch it but tomorrow is another day.

 

Ok here is what I had to do to get fuel to flow constantly.
This is a pic of the 5/16" filter with a 1/4" return line that was purchased from AZ and installed to get the return gas back to the tank. Also I still placed a pressure gauge and a clear filter in the pressure line. BTW the pump only puts 5-7 pounds of pressure into the system.




Another pic of the filter w/ a return line already built in.



This is a pic of my fab work to install a 1/4" bung and port into my filler tube. What you can't see is that the return line is fed thru the bung and put into the tank on the inside of the filler tube.


I ditched the Holley Red Pump cause I received very bad technical support from Holley. They couldn't answer my questions and satisfy my curiosity. I told the tech about my heat problem with the motor of the pump and he suggested to run a return line to help the pump not work so hard. That's why I did all this work in the first place. I received a replacement pump and it did the same thing. I returned them both for my money and purchased a Carter 4600HP and it works perfectly. So, as of right now my fuel pump and fuel line problems are solved until something else happens. Thanks to all for the great advise.

Picture of new fuel pump and filter.

 

Carter makes good stuff, and I like that it says straight out that it's good on gasohol. New layout looks good! Is there an orifice in the 1/4" connection on the filter?

 

No I did not put one in. I just tested the system before putting it back together and the flow to the tank seemed slow and steady enough that the pressure would stay. I ran the truck 15 minutes after it was together and the pressure on the gauge never went below 5 pounds while the flow was still running the same to the tank from the return line on the return filter. BTW was this filter with the return line in it what you might have been looking for? I could have fabbed a connection to place an orifice in the line, but after testing, it didn't look like I needed one. Also, sorry to hear about your heads.

 

Most of those filters already have an orifice in the return connection. If you look up the connection, you can see a little disc with hole that is pressed in. Do you have a P/N for it?

 

Alls well that ends well.

 

Yes AX you are right. Tough love for a truck makes one do things that end well.

Ross, here is what I used and I got it at Autozone: the P/N is
Duralast - FF3421DL or FRAM - G3499




Both of you, Thanks for all the help and encouragement.