Learn me: Fuel Cells

Had a bad day working on or attempting to work on the Escort yesterday.

One of the main sources of my displeasure is the fuel tank, namely the huge shield that covers the whole thing and overlaps far enough on the passenger side to make sure you can't get a ratchet up to the trailing arm unless you mangle the shield.

I'm thinking about just dropping the tank to make everything back there easier to clean up and deal with. (Especially now that it turns out i get to make all new brake lines WEEEEEE!!!!)

If i drop this thing, i'm not putting it back on.

So learn me fuel cells. I can go as small as a 5 gallon cell in my class. (I'd want 10 gallon.)

Is this going to get real expensive? In-line pump, fancy lines, fittings, etc etc etc...

How to attach cell to car? I have a big spare tire well back there. Safety things?

2001-2010 Toyota Prius has a 10-gallon bladder tank, available at junkyards for $50-$100. I'd just use all the Toyota parts with it - filler neck, pump, etc - and change to Ford wiring and plumbing at "soft" junctions.

Your biggest problem would be maintaining fuel pressure.since it is a no return system.

iceracer wrote: Your biggest problem would be maintaining fuel pressure.since it is a no return system.

Didn't think about that... you can't make a return-style system with a fuel cell?

There's $100 cells and $600 (and up) cells. The $$$ are FIA ft3 certified - metal container, rubber bladder, foam baffling, roll over valve and usually a few AN fittings for in/out/vent. The metal cans have a mounting flange. Cheap cells are a container or container and bladder without the cert. (which lasts about 5 years). Check your rules on what you need. I'm figuring it's going to get a little spendy to get a log a book for the TR4 since I have to go the FIA ft3 route.

Rules are SCCA Solo SMF...

I'd probably get a nice one. I was initially thinking a budget of $500 for the whole shebang if i were to do it, but i can stretch to do it right the first time. It was on the agenda for next iteration of the build anyways.

Car is a hatchback, which i believe has some ramifications for safety rules.

In reply to 92CelicaHalfTrac:

You can get fuel cells from a number of places, and even pick up a used one on the cheap. Just about every fuel cell can be configured for any fuel system or fuel type, carb/efi, diesel/gas/meth, you name it.

If you are going real racing and need to meet real rules, you need a real fuel cell which will cost real $$$$ (notice: 4 $ means a lot). These fuel cells are full containment steel containers, have thick fuel bladders, are full of fuel resistant reticulated foam and have FIA certification.

A cheaper alternative is a poly tank/bladder combo like the well-cell from ATL that fits in the spare tire well. I run one of these in my car and it works great. It's cheaper ($600-$800) than the cell above but it's still FIA rated. The downside here is that it has to be separated from the drivers compartment and you can't do any maintenance on it (I'll get to that later).

The cheapo what-are-rules fuel cell is a basic poly or aluminum fuel cell (using that term loosely here) from Summitracing that has no certification, no foam, and probably doesn't even have a mount option for a fuel sender. These are very cheap, usually less than $400, and you can add foam to them if you like at your own expense, BUT, all of these tanks are ineligible for real racing because they lack FIA certification.

Maintenance is important for fuel cells. Most folks don't know but fuel cells don't last long. Most bladders live about 3-5 years, and develop cracks or just age-out. The certification on a fuel cell is 3-5 years depending on the cert and tank. Once it's past it's cert you have to recertify the bladder or replace it. What about the nice poly-bladder combo well-cell? Those you have to recertify or replace the whole tank because the bladder is integrated into the tank. New bladders cost $400-1000+ depending on if its a normal size or a custom job.

Hrmmmm, thanks!

I need to look into the well-cell. I appreciate all the info!

[edit]

Is this what you're talking about? http://www.carshopinc.com/images/ATL171110%20001.JPG

Do you have pictures of how you mounted yours?

In reply to 92CelicaHalfTrac:

I have the 12 gal unit but ATL also make a 10 gal. I've found the extra capacity comes in handy.

http://i93.photobucket.com/albums/l44/humblewolf/Lucy/HPIM0221.jpg

92CelicaHalfTrac wrote:

iceracer wrote: Your biggest problem would be maintaining fuel pressure.since it is a no return system.

Didn't think about that... you can't make a return-style system with a fuel cell?

Sure, it can be done. Just need different parts.