I had to use the Internet Wayback Machine to find this from his Feb 2013 newsletter: Paul Yaw (the guy behind Injector Dynamics) wrote this back in 2013. One size down in comparison to supply line is a good rule of thumb, for added comfort. Now, if you consider that most fuel is returned at idle (least fuel injected), then you need to engineer the line to be large enough in diameter, to prevent pressure building up in the return line. ![]() This allows for more space for the fluid to flow, but also, because the same amount of fluid having to fill in more space, fluid slows down, in turn reducing drag. So to counteract this, a return line diameter is increased. This in turn would increase the pressure in the return line, and thus affect your regulated pressure as well. Very little fluid would flow, because most of it would catch the inside wall of the line. So in your same diameter return line scenario, you'd have a lot of drag. But fluid is sticky, and likes to grab onto surfaces. More fluid/pressure, higher flow, less fluid lesser. Ifyour return line was the same size as the orifice on the regulator, then the fluid passing through would have to flow at higher speeds, directly dependent on the pressure and amount of fluid that is flowing. After the orifice, the line is opened to atmosphere (indirectly via fuel tank), so there's atmosphere pressure there, or no gauge pressure. That's where your injectors are, and by connected vessel fluid dynamics (apologise for the poor translation), injectors are under this pressure too. ![]() The orifice on your pressure regulator (in combination with a spring loaded valve) regulates the amount of pressure on the inlet line. I'm no doctor of physics, but I'll try to explain, until someone more experienced pitches in.
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