Ameer Randolph
Installing a fuel cell can be a complex process, and there are many factors to consider, such as the type of fuel cell, the location of the fuel cell in the vehicle, and the materials used for the fuel lines. It is important to ensure that the fuel cell is installed correctly to prevent leaks and damage to the vehicle. The installation process may involve disconnecting and reconnecting fuel lines, ensuring proper ventilation, and securing the fuel cell in place. Some fuel cells may come with foam to reduce fuel movement, which will need to be cut to fit the surge box. It is also recommended to install a fuel filter between the fuel cell and the fuel pump.
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What You'll Learn
Inspect the fuel cell compartment for rough spots and ensure adequate ventilation
Inspecting the fuel cell compartment for rough spots and ensuring adequate ventilation are crucial steps when installing fuel cell lines. Here's a detailed guide on these important procedures:
Inspecting for Rough Spots
Before installing a fuel cell bladder, it is essential to inspect all edges and surfaces inside the fuel cell compartment for any rough spots or sharp edges. This inspection process helps identify potential sources of puncture or abrasive damage to the fuel bladder. By smoothing out any rough spots, you can reduce the risk of damage to the bladder during installation and ensure its integrity throughout its service life.
Ensuring Adequate Ventilation
Adequate ventilation in the fuel cell compartment is crucial to account for any fuel vapour transfer through the bladder walls. Proper ventilation helps prevent the buildup of fuel vapours, reducing the risk of ignition and explosion. Ensure that the external vent line is plumbed and oriented correctly. Plumb the vent line in a vertical direction, exceeding the tallest point in the fill system, and then run it downwards to the desired venting location. Pad or tape the edges of any compartment openings to further enhance safety. Additionally, consider the type of fuel and its vapour characteristics. For example, racing fuel bladder materials degrade faster in high-moisture environments, so it's important to avoid consistent exposure to high humidity or standing water.
To ensure a safe and effective installation, always refer to the manufacturer's instructions and guidelines, as well as industry best practices. Taking the time to thoroughly inspect and prepare the fuel cell compartment will contribute to the overall reliability and safety of the fuel system.
Remember, these procedures are just a part of the entire fuel cell installation process, which includes tasks such as disconnecting and connecting fuel lines, cleaning, and securing various components. Each step in the installation process is important to ensure a safe and properly functioning fuel system.
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Use rubber or steel fuel lines
When installing fuel cell lines, it is important to consider the type of material used for the fuel lines. Rubber and steel are two commonly used materials for fuel lines, each with its own advantages and considerations.
Rubber fuel lines are flexible, making them easy to route and install. They are also generally less expensive than steel lines. However, one of the main concerns with rubber fuel lines is safety. Rubber hoses can be more susceptible to leaks, and even a small pinhole leak can be dangerous and cause a fire. For this reason, some drag strips do not allow rubber fuel hoses. It is essential to keep rubber fuel lines away from the exhaust manifold to minimise the risk of fire. Additionally, rubber lines can collapse under heavy suction, although this is usually not an issue for most carburettors.
Steel fuel lines, on the other hand, are known for their durability and resistance to leaks. They are less likely to be damaged by heat and debris, making them a safer option than rubber lines. Steel lines are also resistant to the chemicals in modern fuel, including ethanol, which can deteriorate rubber lines over time. However, steel lines are generally more expensive and may be more challenging to install due to their rigidity.
When choosing between rubber and steel fuel lines, it is important to consider the specific application and any relevant regulations or safety standards. For example, if you plan to take your vehicle to a drag strip, you will need to follow their specific rules regarding fuel line materials. In some cases, a combination of both types may be used, with a short section of rubber hose allowed near the fuel pump or carburettor.
Ultimately, both rubber and steel fuel lines can be suitable for fuel cell installations, but it is crucial to prioritise safety and follow the recommended guidelines for your particular vehicle and fuel system setup.
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Install a fuel filter between the fuel cell and pump
Installing a fuel filter between the fuel cell and pump is a highly recommended step to protect your engine. Fuel filters are inexpensive and can save your engine from thousands of dollars in damage. They also ensure better gas mileage and peace of mind.
To install a fuel filter between the fuel cell and pump, you will need to first relieve the pressure in your fuel lines and the fuel filter. Locate the fuel pump fuse or relay in the fuse box and start the car. With the engine running, pull out the fuse or relay. If the engine sputters and dies, you've pulled the right one. Now that the fuel lines are depressurized, you can remove the old fuel filter.
To remove the old fuel filter, locate the banjo fitting and use a wrench to turn the special bolt counter-clockwise until it comes out. Set the bolt aside and slide the fuel line off. Repeat this process for the other side of the fuel filter. Be very careful as the old fuel filter is likely still full of gas. Set the old fuel filter aside and remember to keep the special fuel line bolts and the pressure washer, which is usually made of copper or aluminum.
Now that the old fuel filter is removed, you can install the new fuel filter. The installation process is simply the reverse of the removal process. Don't forget to put the fuel pump fuse or relay back in before trying to start the car.
It is important to note that the fuel filter should be cleaned after the bladder has been filled twice. Additionally, ensure that the fuel cell compartment has adequate ventilation to account for any fuel vapor transfer through the bladder walls.
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Mark the fuel lines before disconnecting
Marking the fuel lines before disconnecting is an important step in the installation of fuel cell lines. This is because it ensures that you know which lines are which when it comes to reconnecting them. It is a good idea to mark which fitting is the vent and return lines. This can be done using blue tape or a sharpie.
For example, if you have a ButlerBuilt Seat, you can mark the fuel cell cover panel for the rear bulkhead mount. This means that you won't have to undo the difficult-to-reach rear bulkhead bolts each time you need to access the fuel cell. You can use a hacksaw and some sheet metal shears for this.
Additionally, if you have an old fuel cell, it is a good idea to clean it before disconnecting the fuel lines. This will remove any built-up gunk and ensure that the lines are properly connected. It is also important to check for any broken wires and ensure that you have 12 volts available at the sender and gauge.
When disconnecting the fuel lines, it is important to use the correct tool. A fuel line disconnect tool can be purchased at an auto parts store. This tool is designed to fit around the fuel line and has an edge that is pressed into the fitting to relieve the pressure and allow the connection to be pulled apart. Alternatively, some people have used a small metal clamp or plastic wrap to disconnect the fuel line. However, it is important to note that using the wrong tool can damage the fuel line.
Overall, marking the fuel lines before disconnecting is a crucial step in the installation of fuel cell lines. It ensures that you can properly reconnect the lines and that the correct tools are used in the process.
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Use a new gasket and cover plate
When installing a fuel cell, it is important to use a new gasket and cover plate. This is because the gasket and cover plate play a crucial role in ensuring a proper seal and protecting the fuel cell from damage.
To begin, you will need to remove the existing fuel cell cover by undoing all the fasteners using the appropriate tools, such as a nut driver, wrench, socket, ratchet, or impact driver. Depending on your vehicle, there may be four sets of fasteners: two on each side, and one each on the top and bottom rows. If the cover is difficult to remove, you may need to use a pry bar or a blunt flat-blade screwdriver. Once the cover is removed, mark and notch it if necessary, especially if you have a bulkhead mount. This will make it easier to access the fuel cell in the future without having to remove the rear bulkhead bolts.
Next, disconnect the fuel lines from the fuel cell closeout plate using a -6 AN wrench. If your hoses show signs of cracking or wear, consider replacing them with a new set of AN hoses and fittings. Loosen the closeout plate bolts with the locating tabs, using a 7/16th inch wrench or socket and ratchet. Swing the tabs out of the way of the engine bay bulkhead and carefully pull the fuel cell out through the driver's compartment. Reuse the cover plate and fittings by blocking all the holes with plugs and cleaning the plate thoroughly.
Now, you are ready to install the new gasket and cover plate. First, collapse the bladder and gently feed it through the access space, ensuring it expands into all corners of the container. Check the empty bladder for any signs of foreign object debris (FOD). Then, install the internal vent line, ensuring the hose is not kinked or blocked to allow proper ventilation. Use a brand new gasket and replace the fuel cell cover plate, threading the fasteners loosely in place. Ensure that all plastic washers are in place to prevent leaks. Finally, torque the fasteners to the manufacturer's recommended specifications, typically 40 in-lbs, being careful not to over-tighten them as this can damage the gasket seal and the fuel cell.
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Frequently asked questions
Inspect all edges and surfaces inside your fuel cell compartment to ensure there are no rough spots that could cause puncture or abrasive damage to the fuel bladder.
Pad or tape the edges of any compartment opening in which the bladder will be installed to reduce the possibility of puncture or abrasion damage during installation.
Remove the access plate and gasket and bag all hardware. Remove the internal baffling foam, numbering each piece with a sharpie so that reinstallation is completed in the correct order.
Collapse the bladder in a way that will provide for the least amount of creasing, and gently feed the bladder through the access space.
It is recommended that a fuel filter be installed between the fuel cell and fuel pump, and that this filter be cleaned after the bladder has been filled twice.
Note: These steps are compiled from various sources and may not be comprehensive. Please refer to manufacturer guidelines or seek professional assistance for a complete and accurate installation process.
