Foam crumbling in fuel cell

[csx4910]

Now I am facing the prospect of replacing the fuel safe fuel cell or the foam and bladder because the foam is already breaking down after only 3-4 years. 3 yrs I have owned it and at least a year the roller sat on the dealer's floor. I cannot believe that Shelby can charge $65000+ for a roller and have so many serious quality issues. I have had issues up the ying yang with Roush but now also the Shelby components. I had much better build quality on my superformance than I do on my CSX costing twice as much. I have found out Shelby took the fuel safe brand bladder and then built their own tank for my car back in 2007. The new ones I understand have the Fuel Safe brand fuel cell

My concern with replacing it is will I have the same problem 3-5years from now? They say 5-8 years on the foam but I cant believe I have to spend another $3-5K on replacing a tank that I would think last longer. Of course Shelby wont do anything about it and Fuel Safe wont becuase Shelby built the tank with their guts in it so they point the finger at shelby. (they also have a defective tank in that they built the fuel pickup in a way that my gas gauge will never work right instead of putting a old fashioned float in the tank like everyone else

I am wondering if anyone has had the same experience. So far twice the fuel filter has caught and trapped the bits of foam but I am on the fence as to how safe it is that the fuel filter will catch them or spend the money to replace the fuel cell

[RICK LAKE]

csx4910 With straight race gas or unleaded straight gas you get 5-8 years. Again it's back to the methanol eating evrything up at a faster rate.
If you have good pre filters to the pump or pumps, just keep an eye on it. You will need to replace the foam t some time.
It helps if you drain the fuel over the winter. ERA fuel tank has 8 bolts and 3 connections. easy to drain and drop in about 10 minutes.
I have not put the foam back in my tank after installing new fuel pumps in tank. Has long as I carry 1/2 tank of fuel no problems racing. I don't feel any real weight transfer from right to left on turns. I do have the double gas cap setup for the car.
Take out the foam and drive the car, there should be 2 -3 baffles inside the tank that will help control fuel sliding around in tank. Rick L.

[John Owen]

The Fuel Safe Pro cell in my oldest car failed after 8 years, the newer one after 6. In both cases the bladder was covered in cracks that that leaked fuel into the tank and outside through drain holes. The foam interior was still intact in both cases. The 10% ethanol fuels were slow to appear at the stations I use, which probably extended their life.
If the Shelby tank containing your bladder does not have a drain hole in the bottom, you may find fuel between the bladder and tank. Fuel Safe cells have these holes as it is the only practical way to detect a failed bladder. You can imagine how much crash protection a bladder with severe cracks is going to provide.
As to removing the foam, there are no internal baffles in the bladder of most cells, and the foam provides structural support to the bladder when it is empty.
As stated, the problem is ethanol - the old Pro fuel cells like mine were not designed for alcohol fuels - the new Pro cells have included alcohol blends on their approved list of fuels. My replacement bladder is made of a different material, and is much more expensive than the old ones. I'm not sure how much confidence they have in this new material, as the warranty decreased from five years to two. My older car is only a street car now, so I will replace the cell with an aluminum gas tank, giving up some safety in a rear end collision, rather than go through this every few years.

[601HP]

Would you consider having Nick Acton make an aluminum tank for you? His tank will have baffles and won't require a bladder or foam. The cost for Nick's unit is far less than what you stated a replacement fuel cell will cost.

I have one of his tanks. It's a nice piece.

David

[mickmate]

If you need a bladdered tank for track requirements you're kinda stuck. Dave has the big 42 in his car. You could go that route for similar money or the same size as you already have here PhotoPost Classifieds - Leaky Bladder? Tank for CSX framed cars - Powered by PhotoPost Classifieds and save yourself some cash.
Of course this one has an inductive tube solid state sender that almost works right.

[mpanten]

What would cost 3-5k? cant you just replace the foam and the liner? if not have someone else make you one like ATL. I replaced my pad and liner for 500 dollars. Not cheap but a heck of a lot better than 3-5k. As far as the gas gauge goes thats a tough battle, the foam makes it difficult to work correctly.

[csx4910]

The tank is about $3K plus labor from Fuel Safe is my understanding

[mpanten]

So you can just replace the bladder and foam? If not have ATL make you one where the foam and liner is replaceable.

[razerwire]

I had to replace the foam in My Bennett car. It has ATL tank and foam is like bricks that you take out and replace. Was not a hard job. ATL has a gas gauge at the tank that is vertical with float that spins on twisted shaft, just need to cut round hole through new foam bricks, Its a mechanical gauge that just needs clearence. Don't know current prices.

[mpanten]

Originally Posted by razerwire

I had to replace the foam in My Bennett car. It has ATL tank and foam is like bricks that you take out and replace. Was not a hard job. ATL has a gas gauge at the tank that is vertical with float that spins on twisted shaft, just need to cut round hole through new foam bricks, Its a mechanical gauge that just needs clearence. Don't know current prices.

I have the same thing but still cant get the gas gauge to work right, costs about 500 for new foam and liner.

[csx4910]

Mickmate, is that tank a bolt in exact fit for the csx or will it require modification? I dont plan to ever race mine and I like the safety of a fuel cell but not the cost of having to replace it every 3-5 years.
Ron

[RodKnock]

Not sure if would fit your CSX, but how about a replacement gas tank from Kirkham?

[mickmate]

Yes the pictures show it mounted in 4772 my car. Give me a holler if you have any questions.

[Full Throttle Al]

I gave up on the idea of having to replace the fuel cell every few years and just went with a new tank with baffles from Kirkham. Added a Centroid fuel level sender unit calibrated to the tank for an accurate fuel level. Very happy with my decision. I think the tank from Kirkham, 30 gallons, was $1400

Alan Sorkey
Shreveport, LA
CSX4083

[KarlCSX2498]

Hello, I have one of the comp tanks from Nick at Acton Custom, I highly recommend his products and the tank installed perfectly. I have posted a foto of the tank installed before the body was installed.
regards, Karl

[csx4910]

Decided and bought new tank without foam but with regualr baffles from Mickmate for $650 for 24 gallon tank. The 42 would of been nice but not worth the extra $$$ and now I wont have to worry about replacing the foam every 3 years or it clogging up the fuel filter. Thanks for all the help Mickmate and thank you everyone for input and suggestions.
Ron