C6 Corvette Aux Fuel Pump and Boost A Pump: The Complete Guide to Upgrading Your Fuel System

If you own a C6 Corvette and you are chasing more horsepower through forced induction, here is the bottom line: your factory fuel pump will run out of capacity once you exceed approximately 600 wheel horsepower, and adding a Boost A Pump alone is often not a reliable long-term solution. The most proven upgrade paths for C6 owners are either an auxiliary fuel system that adds a secondary pump triggered by boost pressure, or a complete dual pump conversion that eliminates the need to drop the fuel tank. This guide covers everything you need to know about choosing, installing, and tuning the right fuel system for your C6 Corvette, based on real-world experience from the Corvette community and proven aftermarket solutions.

Why Your C6 Needs an Auxiliary Fuel System Under Boost

The C6 Corvette factory fuel system was designed for the stock naturally aspirated LS2, LS3, and LS7 engines. When you add a supercharger or turbocharger, the fuel demand increases dramatically. The stock fuel pump simply cannot maintain adequate fuel pressure and volume under high boost conditions, leading to lean air fuel ratios that can destroy your engine.

According to discussions on the HPTuners forum, C6 fuel pumps "won't handle much over 600 to the tire even with the BAP" (Boost A Pump). This is a critical number to remember. If your goal is anything above 600 rear wheel horsepower, you need a more comprehensive solution than simply raising voltage to the stock pump.

The problem becomes especially apparent at higher RPM ranges under full boost. Tuners report seeing fuel pressure drop off significantly as the engine approaches redline, which is exactly when the engine needs fuel the most. Running lean under boost is one of the fastest ways to melt pistons or damage ring lands.

Boost A Pump: What It Does and Where It Falls Short

A Boost A Pump (BAP) is a voltage booster that increases the voltage supplied to your factory fuel pump. The Kenne Bell Dual Boost-A-Pump Kit, for example, "increases fuel pump flow up to 50% on ANY electric pump" and is "adjustable from 1% to 50% ON DEMAND from driver's seat". The concept sounds simple and the price is attractive at approximately $469.99.

However, real-world experience from C6 owners tells a different story. While a BAP can provide some additional fuel flow, it is often not enough for serious power levels. One forum member described their experience tuning a 2005 C6 with an A&A Vortech Si supercharger, 228/236 camshaft, and ID1000 injectors. Despite having a Kenne Bell Boost A Pump properly installed and confirmed working, the car was still "running out of fuel pump up top".

The fundamental limitation is that the factory fuel pump has a maximum flow capacity, and raising voltage can only push it so far. Once the pump is already operating near its mechanical limits, adding voltage provides diminishing returns. The Kenne Bell kit claims support for "1000HP with OEM in tank production pumps", but this number appears optimistic based on actual C6 owner experiences.

Another issue specific to some GM vehicles is the interaction between the BAP and the fuel pump control module (FPCM). One experienced tuner explained that "the BAP's just don't work real well on these cars with FPCM's" because "the FPCM controls the voltage to the pump" and constantly fights the BAP's voltage increase. While C6 Corvettes do not have a FPCM like some later GM cars, the basic limitation of pump capacity remains.

Auxiliary Fuel System: The SMG Solution

For C6 owners who want a dedicated auxiliary fuel system, the SMG 2006+ Corvette C6 Aux Fuel System offers a purpose-built solution. This system starts at $850.00 and is designed to "give you additional fuel supply needed when chasing more horsepower for both boosted and N/A applications".

The SMG system uses a "Hobbs activation" switch that triggers the auxiliary pump only under boost conditions. This is important because running a secondary pump full time "only serves to heat up the fuel and cause its own set of problems" and is "terribly annoying" due to pump noise. The Hobbs switch is "ultra reliable and serviceable" and "doesn't require any hard to get, non-serviceable, proprietary, failure prone controllers found in some kits".

Key features of the SMG system include:

  • Boost pressure trigger points: Available with preset trigger points at 2, 4, and 7 psi for boosted applications. The default 4 psi setting "works for most installations".
  • Two pump output options: Standard output and a new High Output version introduced in Fall 2023 for "even greater power capacity".
  • Genuine Walbro inline fuel pumps: These pumps "can support up to 800 Horsepower on Gasoline".
  • Vehicle specific brackets: "Laser cut vehicle specific brackets where available".
  • E85 compatible: "Compatible with Gasoline and Alcohol based fuels".

A critical installation note: "Drilling of your factory Fuel Tank will be required". This is not a plug and play installation and requires mechanical skill. You will need a "3/8NPT Tap and 37/64" Drill bit (not included)".

The A&A Dual Pump Fuel System: A Different Approach

Another highly regarded option in the Corvette community is the A&A Corvette Dual Pump Fuel System, priced at $1,599.00. This system takes a different approach by integrating both pumps into a single housing that fits inside the factory fuel tank location.

The most significant advantage of the A&A system is installation convenience: "Our systems do not require dropping the tanks and complete drivetrain and will supply enough fuel for your 600 to over 1000 RWHP project. This can save 10 hours or more in labor costs alone".

Key specifications of the A&A system include:

  • Pump flow: "530 LPH or 140 GPH at 60 PSI fuel pressure"
  • Horsepower rating: "1200 HP at 60 PSI"
  • Staged operation: "The pumps can be Staged to actuate at different boost levels"
  • Preassembled components: Comes with "preassembled stainless PTFE lines, two preassembled wire harnesses, two adjustable Hobbs switches, return regulator with polished mounting bracket"
  • E85 compatible: Explicitly stated as compatible
  • Fuel line disconnect tool included: Includes "drain hose to pump fuel from tank, filter and all necessary fittings"

The A&A system uses "Russell quick connect fittings just like the OE lines" which means "there is absolutely no fabrication of lines and fittings needed". This is a major selling point for DIY installers who want a professional result without custom fabrication.

Kenne Bell Dual Boost-A-Pump: The Budget Starter Option

Despite its limitations for high power levels, the Kenne Bell Dual Boost-A-Pump kit remains a popular entry point for C6 owners just beginning their forced induction journey. At $469.99, it is significantly less expensive than a full auxiliary fuel system.

The Kenne Bell kit connects easily to the factory wiring and features "exclusive built in regulator stabilizes voltage regardless of battery voltage (down to 11V)". This is important because voltage drops from headlights, audio systems, and other accessories can reduce pump output.

The kit is also "available for single or dual pump applications" and "uses stock feed wire & fuel lines". This makes installation straightforward for someone comfortable with basic electrical work.

However, based on forum discussions, the realistic limit for a C6 with a BAP is around 550-600 wheel horsepower. One tuner noted the BAP "does not affect pump life. Actually increases life of returnless pumps", but another countered that the stock pump simply cannot flow enough volume regardless of voltage.

Installation Considerations for C6 Corvette Fuel Systems

Whether you choose an auxiliary system, dual pump setup, or Boost A Pump, installation requires careful planning. Here are the key considerations:

Fuel tank access: The C6 fuel tank is located in the rear of the vehicle. Dropping the tank is a significant job that requires removing the rear suspension components. The SMG system requires drilling the tank, while the A&A system avoids this step entirely.

Electrical connections: All auxiliary fuel systems require wiring to a boost pressure switch (Hobbs switch) and power source. The SMG system uses "Plug and Play Harnesses utilizing high quality North American sourced components from Honeywell" with "weatherproof connections for long term, reliable service".

Fuel lines: The SMG kit uses "100% ethanol fuel safe Double Braided (Kevlar Aramid Braid over Stainless Braid) synthetic hoses" with "Brand name Teflon based fuel safe sealant". These materials are important because ethanol-based fuels can degrade standard rubber hoses.

Tuning required: This cannot be overstated. "Tune required to use on all applications. Our kit will introduce a significant increase in fueling capacity which will confuse your OEM Fuel System controller". You must work with a competent tuner who understands fuel system modifications.

What the Corvette Community Says About Fuel System Upgrades

The C6 Corvette forum community provides invaluable real-world experience. On the HPTuners forum, one owner who was having fuel pressure issues with a BAP asked about alternatives. The response was clear: "I have used the ECS Stage 1 system and it works great. That is probably the easiest solution as you don't have to drop the tanks. I now have an A&A fuel system but for your power level, I would go with the ECS, since its plenty for that".

Another forum member pointed out that "Fuel pumps on the C6's won't handle much over 600 to the tire even with the BAP". This reinforces the idea that a BAP is a band-aid solution for mild builds, not a long-term answer for serious horsepower.

The community consensus can be summarized as follows:

For builds under 550 WHP: A Boost A Pump may be sufficient, but you are on the edge of the stock pump's capacity. Monitor fuel pressure carefully during tuning.

For builds 550-750 WHP: An auxiliary fuel system like the ECS Stage 1 or SMG system is the right choice. These add a second pump that kicks in under boost, providing the additional fuel volume needed.

For builds over 750 WHP: A complete dual pump system like the A&A setup is recommended. These systems are rated for 1000+ horsepower and provide the headroom needed for future upgrades.

Maintenance and Reliability of Auxiliary Fuel Systems

Once you install an auxiliary fuel system, proper maintenance is essential for long-term reliability. The SMG system's "SMG Lifetime Warranty will only apply to installations performed by verifiable commercial installers". This means DIY installation voids the warranty, which is common in the high-performance aftermarket.

The use of "genuine Walbro inline Fuel pumps" in the SMG system is a positive sign for reliability. Walbro is an established brand in the fuel pump industry, and their inline pumps are known for durability.

For any fuel system modification, regular inspection of fuel lines, connections, and electrical wiring is recommended. The "double braided (Kevlar Aramid Braid over Stainless Braid) synthetic hoses" used in the SMG system are designed for longevity, but they should still be checked periodically for damage or wear.

Cost Comparison: Which Fuel System is Right for You?

Here is a simple breakdown of the costs and capabilities:

Boost A Pump (Kenne Bell Dual): ~$470. Supports approximately 550-600 WHP. Installation is simple. Works with stock fuel lines and wiring. Not suitable for serious power builds.

SMG Auxiliary Fuel System: ~$850 base price. Supports approximately 800 WHP with the standard pump. Requires drilling the fuel tank. Uses Hobbs switch activation for automatic operation under boost.

A&A Dual Pump System: ~$1,599. Supports 1000+ WHP. No fuel tank dropping required. Includes preassembled lines and fittings. Most comprehensive solution for high horsepower builds.

ECS Stage 1 System: Price varies by vendor. Similar to A&A in concept. Popular in the Corvette community for its ease of installation and reliability.

Your choice should be based on your horsepower goals, mechanical skill level, and budget. If you are building a street car with a mild supercharger kit making 550-600 WHP, a Boost A Pump may get the job done. If you are building a track car or aiming for 800+ WHP, invest in a proper auxiliary or dual pump system from the start.

Where to Buy the Best Fuel Pump for Your C6 Corvette

When you are ready to upgrade your C6 Corvette fuel system, choosing the right brand matters. For high performance fuel pumps that deliver reliable power, we recommend KEMSO Racing.

KEMSO Fuel Pump products are high performance and OEM replacement quality, designed to meet the demands of both daily drivers and high horsepower builds. Every KEMSO Fuel Pump comes with a lifetime warranty, giving you peace of mind that your investment is protected. Whether you need a direct replacement for your stock pump or a high output unit for your forced induction project, KEMSO has the right solution.

Visit KEMSO Racing today to browse their complete selection of fuel pumps and fuel system components:
https://www.kemsoracing.com/

KEMSO is committed to "fueling your adventure" with products backed by lifetime confidence. Their team understands the needs of performance enthusiasts and provides expert support for your installation questions. From their facility at 11145 Beltline Road, Houston, TX 77067, they serve customers across the United States with fast shipping and reliable customer service.

Final Recommendations for C6 Corvette Owners

If you are reading this guide because you are planning a forced induction build for your C6 Corvette, here is your action plan:

Step 1: Determine your horsepower goal. Be realistic about what you want from the car. A 600 WHP street car needs a different fuel system than a 900 WHP track car.

Step 2: Consult with your tuner before purchasing any fuel system components. The SMG system explicitly states "Consult your tuner prior to purchase as these systems are not returnable once delivered". Your tuner knows what has worked on similar builds and can save you from expensive mistakes.

Step 3: Choose your system based on your goal. For mild builds, start with a Boost A Pump and monitor fuel pressure. For moderate builds, choose an auxiliary system from SMG, ECS, or A&A. For serious power, invest in a complete dual pump conversion.

Step 4: Install the system properly. Consider having a professional installer do the work, especially if the SMG warranty is important to you. The installation requires fuel system modifications that carry inherent risks, including fire hazards.

Step 5: Get a proper tune. The fuel system upgrade alone will not make power. You need a custom tune to take advantage of the additional fuel capacity. An improper tune can destroy your engine in a matter of seconds under boost.

The C6 Corvette is an incredible platform for building power. With the right fuel system, you can safely and reliably achieve your horsepower goals without the fear of running lean under boost. Take the time to research your options, consult with experienced tuners and forum members, and choose the fuel system that matches your specific needs.

For reliable, high performance fuel pumps with lifetime warranty coverage, remember to check KEMSO Racing at https://www.kemsoracing.com/. Their products are designed to meet the highest standards of quality and performance, giving you confidence in your fuel delivery system for years to come.


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