Anyone Make/Buy Custom Alum. Fuel Cell ?
 

I'm almost ready to remove my original LSC poly fuel tank after 10 years of sitting with around 1/4-1/3 of gas in it. The plan is to remove thr tank, empty the (I'm sure stinky) fuel and put in a tank cleaner and follow the manufactures instruction's.

But, I've always wanted to build or buy a custom aluminum fuel cell over the cheap and ugly plastic tank that came with the kit from Lone Star. And now, with my new 428 I have a EFI stack injection system from FAST, I would prefer a EFI fuel cell with the pump inside vs mounting it on the frame and all other system parts, rather than retro my old tank.

A fuel cell is of course, safer. A new tank is not a must, but since I'm using an EFI and need to remove thr tank for cleaning inside, this would be the time to improve my fuel system.

Please give me your thoughts, advise, your choise of tank manufacture, photo's and video.

I had a custom aluminum tank for my Cheetah project built to my specs by RCI in Tyler, TX (RCIracing.com). I worked with Wayne Wilson. ... I started by selecting one of their stock tanks to identify the fittings I wanted, and then told them the dimensions I wanted. Note that they aren't receptive to complicated designs. If you can get by with something with six flat sides. they can work with angled joints and trapezoid shaped end pieces. The cost was not much more than a stock tank.

I had a stainless steel tank made by Rock Valley.
I recommend a baffled sump, because it's a good feature plus the round sump under the tank is cool looking from the perspective of a driver behind. ;-)

Doesn't foam in the tank automatically lower the usable lifespan of the tank?

What do you mean by,...round sump under the tank ?

Do you have a pic ?
About how much was yours ?

Were you guys able to still use the Cobra's LaMans fuel filler ?

In my experience, the filler is connected to the tank by a rubber hose. The key to making everything work together is to get the filler on the tank fit the same size hose as the filler on the fender. The even sell adapters that let you fit a larger hose on a smaller filler if you can't get both fillers the same size.

Tank was relatively shallow so the combo fuel pump/spiral baffle assembly needed the bumpdown space. Pump is accessible from the top of the tank. Spiral baffle keeps fuel around the pump for cooling purposes.
Lots of variables in the cost. I provided them with an original tank and let them keep it...it was a tank they hadn't reproduced before and wanted to add to their CAD design files, gave me a discount for that. Adding to the project cost was the cost of the pump assembly. Plus, for comparison purposes, it was a while ago...

It came with an attached SS filler tube. Fit like it was original equipment.

Someone else took and published pictures of the fuel pump assembly with the spiral baffle that drops down into the sump of the tank...

https://www.corvetteforum.com/forums...s-img_3531.jpg

My tank: below...

OK....Kevin you asked for it..... this will be long but very infromative...

First you need a Schematic or Drawings of what you want a Fuel Cell company to manufacture for you.... Here's an example

http://www.clubcobra.com/photopost/d...el_Cell_35.jpg

Then you need to design a Collector... inside the fuel cell for a couple of reasons .... one for a reserve.... but also a collector is used to capture fuel from the corners of the fuel cell.

http://www.clubcobra.com/photopost/d...el_Cell_36.jpg


Next you get the fuel cell in then you have to start modifying.

http://www.clubcobra.com/photopost/d...el_Cell_38.jpg

Here's the Passenger side of the cell which has the Fuel Level Sender and the Vent Check Valve for roll over.... also the same Vent is on the other side of the Fuel Cell. When fuel cell is full and you go around a corner one of the vents will be open ....

http://www.clubcobra.com/photopost/d...l_Cell_201.jpg

Here's the Collector and as you can see it has a main fuel line and a Reserve line in the Collector..... it also and you can't see it ...but over the top of the collector is 2 hoses coming from the internal fuel pumps in the corners of the fuel cell so when in a turn you always have fuel being pumped to the Collector. (On Throttle in a Sweeping Corner all of the fuel will be swept to the rear of the cell and on the opposite side of the turn)....


http://www.clubcobra.com/photopost/d...uel_Cell_6.jpg

Here's what he Reserve Pick up looks like in the Collector and just a foot note we run on the Reserve Pick up all of the time.

http://www.clubcobra.com/photopost/d...uel_Cell_8.jpg


Here's where the Main and Reserve come out of the Fuel Cell.
This photo doesn't show the Electrical Connection for the 2 Pumps inside of the Fuel Cell. The Connectors would be below each Fuel output fitting. and those are -8 Fittings going forward.... Return line is -6 returning to the Cell.

http://www.clubcobra.com/photopost/d...el_Cell_21.jpg


Here's where we open up the Fuel Cell and install the internal Pumps and collector basins. we had to cut away some of the Sponge Foam to fit the Collectors in the Cell

http://www.clubcobra.com/photopost/d...0/DSC06849.JPG

These are the Collectors inside the Cell in each corner.... the balls roll inside each of the holes on the 3 sides of the Collector. and the out put for the fuel pump goes to the Collector in the front of the Cell so that the motor never runs out of fuel.

http://www.clubcobra.com/photopost/d...uel_Cell_3.jpg

Then we seal it up and then insulate the out side from any heat

http://www.clubcobra.com/photopost/d...el_Cell_17.jpg

The Silicone and Insulation prevents Heat and any part of the Chassis rubbing on the Cell.

http://www.clubcobra.com/photopost/d...el_Cell_30.jpg

http://www.clubcobra.com/photopost/d...el_Cell_31.jpg

http://www.clubcobra.com/photopost/d...el_Cell_17.jpg


I must tell you when you do a Fuel Cell right.... it can get expensive...

And important issue is that the Angle on the fuel cell in the car needs to be between 8*degrees and 10*degrees to the ground so if I decided to make a Aero Device for the bottom of the Fuel Cell it would assist the down force on the rear of the car at speed.... how ever we did not need it ... the Wing worked fine.

Sorry for the long post.

Now Morris, a long post from you, I always enjoy what you have to say and always informative, including this one. :cool:

I'll read over in tonight and get back to you. The cost is a concern and I don't race anymore, so a high dollar, high tech unit isn't a must need, but at the same time it's a much better and safer system, even if it will be mostly street driven.

What is your best guestiment, on the cost of one your describing here ?

How far down does the tank sit below the Cobra's rear body/valance ?

Curiosity point for you fuel cell aficionados:

What is the usable life of the foam material?

It used to be a few years at most - has technology made any significant increase?

The cost will vary......Fuel Safe Cell ....about $2500-$3000......internal pumps....$300......connectors and wiring....$250....approximately....

The fuel cell is even with the rear valance and pitched down to the frame rails so that our Torsional plate and the fuel cell meet ...

Tom

With the gas of today the fuel cell companies require the foam to be changed every 5 years......(fuel + methanol)

We only run Sunoco 112 octane race fuel ⛽️ so we don’t have to follow that rule and we drain our fuel cell when KMP259 is idle for any time. Fuel is not in the cell that long.....

email Tom, in Cali
tommy2899@gmail.com

Lts of tank experience.....:cool:

:confused: