Sylvie Willis
Setting up a fuel cell race car involves several key considerations and steps. Firstly, it's important to understand the two main types of fuel cells: gasoline/diesel fuel cells and hydrogen fuel cells. Gasoline cells are reinforced tanks with baffles and sometimes a bladder, while hydrogen fuel cells generate electricity by combining hydrogen with oxygen. Fuel cells are designed to prevent fuel spills during races and are often made of steel or aluminum. Installation involves draining fuel, disconnecting hoses and fuel lines, cleaning, and reassembling with new parts. Maintenance and safety checks are crucial, as fuel cells have a limited lifespan and can develop leaks over time.
Characteristics and Values of Setting Up a Fuel Cell Race Car
| Characteristics | Values |
|---|---|
| Fuel Cell Type | Gasoline/diesel or hydrogen |
| Fuel Cell Composition | Outer can/enclosure, bladder, and foam baffling |
| Fuel Cell Enclosure Material | Steel or aluminum |
| Fuel Cell Lifespan | 5 years with a 2-year recertification option, up to a maximum of 7 years |
| Installation Steps | Drain fuel, disconnect fuel filler hose, remove seat, undo fasteners, remove fuel cell, clean, install new fuel cell, reinstall fasteners and seat |
| Maintenance | Drain cell before off-season storage and after each event if using alcohol-bearing fuel |
| Safety Considerations | Prevent fuel spills during racing incidents, inspect for delamination and cracking, use protective tape on bladder edges and bottom surface |
| Fuel Cell Sources | Kanga Motorsports, Pegasus Auto Racing Supplies, Jazz, CSR Performance, Fuel Safe, ATL |
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What You'll Learn
Fuel cell installation
Fuel cells are designed to prevent fuel spills in the event of a crash. They generally consist of three parts: the outer can or enclosure, the bladder, and the foam baffling. The fuel cell enclosure is typically made of steel or aluminium.
Before installing a fuel cell, it is important to check for leaks and cracks. Fuel cell bladders do not last forever and over time they will start to leak. Cracks cannot be repaired in the field and a cracked bladder must be replaced.
- Drain all the fuel out of the car.
- Disconnect the fuel filler hose from the fuel cell side.
- Remove the seat from the car.
- Undo all the fasteners holding the fuel cell cover in place.
- Disconnect the fuel lines from the fuel cell close-out plate.
- Loosen the close-out plate bolts with the locating tabs.
- Swing the tabs out of the way of the engine bay bulkhead and pull the fuel cell out through the driver's compartment.
- Clean the fuel cell cover plate and fittings.
- Reinstall the fuel cell and cover, and tighten the fittings.
- Reinstall the seat.
Some additional considerations:
- If you do not have an in-tank fuel pump, now is a good time to upgrade.
- Mark the vent and return fittings before disconnecting the fuel lines.
- If your hoses are old, replace them with a fresh set of AN hoses and fittings.
- If you are racing, you will need to use a bladder.
- Use protective tape along the edges and bottom surface of the bladder to protect against chafing.
- Make sure to tighten the fittings coming out of the cell to prevent leaks.
- If you are using a fuel injection pump, you will need to have a return line.
- Use a fuel filler neck with a cap to keep the installation street legal.
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Fuel cell maintenance
Pre-Installation Maintenance:
Before installing a new fuel cell, it is crucial to inspect the inside of the enclosure for any debris or rough edges that could potentially damage the cell. Many builders recommend using protective tape, such as Leading Edge Tape, along the edges and bottom surface of the bladder to protect against chafing. Additionally, it is important to read and follow the manufacturer's instructions, which include essential safety information and guidelines.
Regular Maintenance:
During the racing season, it is important to regularly inspect the fuel cell and bladder for any signs of damage or wear. Look for delamination (the elastomer coating separating from the aramid fabric) and cracking in the elastomer coating, which can appear as dark areas where fuel and contaminants have soaked into the inner fabric. Cracks cannot be repaired and a cracked bladder must be replaced, so regular inspections are crucial.
If you are using alcohol-bearing fuel, it is essential to drain the cell immediately after each event. Alcohol, along with water, is highly damaging to the bladder and can cause degradation over time. Additionally, ensure that you inspect the fuel fill plate and the spring that controls the fluid entering the overflow tube. If there is any resistance, replace the spring immediately.
Off-Season Maintenance:
During the off-season, it is crucial to perform a thorough inspection and maintenance of the fuel cell. Pull the bladder from its casing and inspect it closely, especially if the vehicle has been involved in an accident. Bladders are designed to fold and bend during accidents to prevent fuel spillage, but this can cause stress and damage to the bladder.
Before removing the bladder, ensure you take safety precautions as the fuel cell contains explosive liquids, and static electricity could cause a dangerous situation. When removing the bladder, fill it with water first, then drain it before lifting the foam out to ensure no fuel is remaining.
Replacement:
Fuel cell bladders have a finite lifespan and will eventually need to be replaced. Manufacturers have the option to inspect and recertify cells, but this is limited to a maximum of 7 years. Bladders made from different materials, such as rubber, Kevlar-Aramid, or Nylon, may have varying lifespans, so it is important to consult the manufacturer's guidelines.
Additional Considerations:
When maintaining and replacing fuel cells, it is important to consider the regulations and standards set by racing organizations. Many require fuel cells to be certified to specific standards, such as the FIA FT3, FT3.5, or FT5 standards. Ensure that you have the necessary certificates and holograms to present during tech inspections.
In terms of convenience and safety, the filler neck arrangement of the fuel cell is an important consideration. Some arrangements may be inconvenient or even less safe than a stock tank, so it is worth researching and discussing with experts to make an informed decision.
By following these maintenance instructions and staying vigilant about the condition of your fuel cell, you can help ensure the safety and performance of your race car.
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Fuel cell safety
Fuel cells generally consist of three parts: the outer can or enclosure, the bladder, and the foam baffling. The fuel cell enclosure is typically made of steel or aluminium and acts as the cell's first line of defence against damage. The outer can or enclosure is crucial for safety as it protects the inner components of the fuel cell from external damage.
Before installing a fuel cell, it is important to inspect it for any signs of damage or defects. Look for signs of delamination (the elastomer coating separating from the aramid fabric) and cracking in the elastomer coating. Cracks sometimes show up as dark areas where fuel and other contaminants have soaked into the inner fabric. They most often appear along folded edges and around the base of moulded necks or spouts. Cracks cannot be repaired and a cracked bladder must be replaced.
When installing a fuel cell, it is important to follow the manufacturer's instructions and safety guidelines. This includes using the correct tools and techniques to avoid damage to the fuel cell and surrounding components. It is also important to ensure that the fuel cell is properly secured and all fasteners are tightened to prevent vibration and movement during use.
After installation, regular maintenance and inspection of the fuel cell are crucial for safety. Manufacturers typically offer inspection and recertification services for fuel cells before they expire, with a total maximum lifespan of 7 years. It is important to drain the fuel cell completely before off-season storage and after each event if using alcohol-bearing fuel.
In the case of hydrogen fuel cells, hydrogen is a highly flammable gas and can cause fires and explosions if not handled properly. Hydrogen is colourless, odourless, and tasteless, making it difficult to detect leaks. Sensors and remote hydrogen sensing technology are now available to detect leaks and mitigate safety risks.
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Fuel cell construction
Fuel cells generally consist of three parts: the outer can or enclosure, the bladder, and the foam baffling. The fuel cell enclosure is typically made of steel or aluminium. It is the cell's first line of defence against damage.
The old Goodyear, Firestone, Uni-Royal, and Marston cells were made of rubber with a layer of fabric reinforcement. They lasted a long time but were not as strong as the elastomer-coated aramid materials that are now required by FIA standards. Cracks in the elastomer coating cannot be repaired in the field and will not heal on their own. A cracked bladder must be replaced.
If you are racing, then it is important to have a bladder in your fuel cell. One user on Race-DeZert shared that his wife's ranger had a fuel tank that looked like a fuel cell but was just a tank. During a race, it got nerfed and started to leak. It was switched to a true fuel cell before the next race.
You can build a fuel cell out of aluminium. If you want to make it street legal, use the stock cap and screw the metal part to the top of the filler, then connect the return line to the cell. You will also need to have a return line, which is the difference from a regular carbed set-up from a plumbing aspect.
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Fuel cell racing regulations
Fuel cells are an integral part of race cars, with regulations focusing on safety and performance. Here are the key fuel cell racing regulations to consider:
Safety Standards
To prevent fuel spillage and minimize fire risks, racing organizations mandate the use of safety fuel cells. These cells are designed to withstand tears, punctures, and heavy impacts without leaking. The bladder, a critical component, must be made of high-tech materials like aramid fibers coated with elastomers, ensuring flexibility and strength.
Certification and Inspection
Fuel cells must be certified to meet specific standards, such as the FIA FT3, FT3.5, or FT5 standards. This certification is valid for a limited period, typically five years, with an option for manufacturers to recertify for an additional two years. It is the responsibility of the racer to present the certification during tech inspections, and any recertification must adhere to current FIA standards.
Fuel Cell Components
A typical fuel cell consists of three main parts: the outer can or enclosure, the bladder, and the foam baffling. The enclosure, made of steel or aluminum, acts as the first line of defense against damage. The bladder contains the fuel, and the foam baffling acts as a sponge, preventing fuel leakage in case of a rupture.
Installation and Maintenance
The installation process for fuel cells involves marking fuel lines, disconnecting and reconnecting hoses, and ensuring proper fastening. Regular maintenance includes inspecting the bladder for wear, delamination, and cracking. Racers should also drain the cell completely before off-season storage, especially if using alcohol-bearing fuel.
Racing Organization-Specific Regulations
Different racing organizations, such as NASCAR and FIA, have their own specific fuel-related safety requirements. NASCAR, for instance, closely regulates fuel lines, fuel pumps, mounting methods, and connections. They also specify the use of a metal container and have strict rules against reducing the amount of foam in the fuel cell.
These regulations ensure the safe and efficient use of fuel cells in race cars, with a focus on minimizing fire risks and maximizing driver protection. Racers must adhere to these regulations to participate in competitions, and it is essential to stay updated with any changes or advancements in the field of fuel cell technology and associated rules.
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Frequently asked questions
There are two types of fuel cells: gasoline/diesel and hydrogen. Gasoline cells are reinforced tanks with baffles and a bladder, while hydrogen cells take hydrogen gas and combine it with atmospheric oxygen to produce water and electricity.
First, drain all the fuel from the car. Disconnect the fuel filler hose from the fuel cell side. Remove the seat from the car. Undo all the fasteners holding the fuel cell cover in place. Loosen the closeout plate bolts and remove the fuel cell. Clean the cover plate and fittings, and then reinstall the fuel cell and cover.
Fuel cells are designed to prevent spilled fuel in the event of a racing incident. However, they are not without risks. Some cheaper fuel cells have difficult-to-open fillers, they vent to the local atmosphere, and they have easy-to-break-off fittings. It is important to regularly inspect fuel cells for any signs of damage or leaks.
Many road racing organizations require fuel cells to be certified to FIA FT3, FT3.5, or FT5 standards. Fuel cells have a maximum lifespan of 7 years, after which they must be replaced.
