Ameer Randolph
A fuel cell in a race car is essentially a gas tank, usually boxy and mounted inside the vehicle. It is a critical piece of safety equipment, as its material strength and design help prevent fuel spillage in the event of a crash. Racing fuel cells are designed to optimise fuel delivery in competitive racing and extreme off-road conditions. They are available in various shapes and sizes and are made from materials such as high-strength plastic or steel with internal bladders. The fuel bladder and foam within the fuel cell keep the fuel from sloshing around and absorb impact energy in a crash. Maintenance of racing fuel cells is crucial, with regular inspections for cracks, tears, and wear marks being necessary to ensure safety and performance.
Race Car Fuel Cell Characteristics
| Characteristics | Values |
|---|---|
| Definition | A fuel cell is a gas tank for liquid fuels. |
| Mounting | Usually mounted inside a vehicle. For trucks and off-road vehicles, they are mounted in the bed. In race cars, they are usually mounted in the truck. |
| Shape | Usually boxy. |
| Reinforcement | Usually reinforced and stronger. |
| Types | Gasoline/diesel fuel cell and hydrogen fuel cell. |
| Gasoline Cell | A reinforced tank with baffles and often a bladder. |
| Safety | Provides safety advantages over factory original gas tanks. Protects drivers in crashes by preventing fuel spillage. |
| Design | Available in several shapes and sizes. |
| Materials | High-strength plastic, steel with internal bladders, aluminium, natural, and elastomer-coated aramid materials. |
| Maintenance | Requires regular inspection and maintenance, especially after crashes. |
| Fuel Types | Alcohol, diesel, E85, and gasoline. |
| Capacity | Capacities vary, including 3, 5, 15, 20, and 25 gallons. |
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What You'll Learn
Safety
Protection in Crashes and Accidents
One of the primary safety features of fuel cells is their ability to prevent fuel spillage in the event of a crash. The material strength and inner design of the fuel cell help achieve this. Additionally, the bladder, made from high tensile strength elastomeric components, is designed to be strong and flexible. This flexibility allows it to deform in the event of an impact, further reducing the risk of fuel leakage.
Fuel Retention
Fuel cells are designed to retain fuel even in the event of a direct impact, roll-over, or deformation of the vehicle. This is due to the layering of safety components, including the bladder and foam baffling. The foam baffling acts like a sponge, helping to prevent fuel from exploding or sloshing around inside the cell, which improves vehicle handling and provides better fuel efficiency.
Strong and Durable Construction
Race car fuel cells are constructed using technologically advanced materials and processes. For example, the current FIA standards require the use of elastomer-coated aramid materials, which are much stronger than the traditional rubber and fabric reinforcement used in older fuel cells. While these new materials have a limited lifespan, they offer superior strength and protection.
Regular Maintenance and Inspections
To ensure the ongoing safety of race car fuel cells, regular maintenance and inspections are necessary. This includes looking for signs of delamination, cracks, or other damage. Cracks can appear along folded edges and the base of moulded necks or spouts. It is recommended to completely drain the cell before off-season storage and after each event if using alcohol-bearing fuel. Additionally, following the manufacturer's instructions and having the necessary certifications are crucial aspects of maintaining a safe fuel cell.
Fuel cells come with safety ratings, such as the FIA ratings of FT3, FT3.5, and FT5, which indicate different levels of bladder material strength. Additionally, some fuel cells have certifications like the AS9100 certification, ensuring they are built to rigorous standards. It is important to check the rules and requirements of the racing class to determine if specific certifications, such as FIA certification, are mandatory.
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Maintenance
A race car fuel cell is a high-performance alternative to a conventional fuel tank. It is designed to optimise fuel delivery in competitive racing and extreme off-road conditions. Fuel cells are pivotal in race cars and high-performance setups, as they offer enhanced safety, performance, and the ability to feed high-capacity fuel pumps.
Race car fuel cells require regular maintenance to ensure optimal performance and safety. Here are some important maintenance tips:
- Inspection and Replacement — It is crucial to regularly inspect the fuel cell bladder for any tears, cracks, or wear marks, especially after an accident. Cracks usually appear along folded edges and around the base of moulded necks or spouts. Bladders with cracks must be replaced as they cannot be repaired in the field and will not heal on their own.
- Drain the Cell — If you use alcohol-bearing fuel, it is recommended to drain the cell immediately after every event. Environmental factors such as ozone, UV light, heat, vibration, and even gasoline contribute to the breakdown of the bladder over time. Alcohol and water can be particularly damaging, so proper drainage is essential.
- Use Protective Tape — Applying a protective tape, such as Leading Edge Tape, along the edges and the bottom surface of the bladder can help protect against chafing.
- Follow Manufacturer's Instructions — It is important to read and follow the manufacturer's instructions for maintenance and care. Keep the certificate that states your cell meets or exceeds applicable FIA standards, as it may be required during tech inspections.
- Off-Season Maintenance — During the off-season, completely drain the cell before storage. This is also the time to thoroughly inspect the bladder and replace it if necessary.
- Installation — When installing a new cell, inspect the inside of the enclosure for any debris or rough edges that could damage the cell.
- Fuel Filter Replacement — Whether using a methanol or gasoline engine, it is recommended to replace the fuel filter during the teardown. Check the threads on the fuel filter and inspect for any debris inside the cap.
- Foam Considerations — If using a fuel bladder and foam setup, ensure that the foam is compatible with your fuel type. Alcohol-burning engines may require special foam, such as ATL's SF110, designed to resist degradation from alcohol.
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Materials
A race car fuel cell is designed to prevent fuel spillage during a crash or rollover. The material strength of the fuel cell is critical to its function.
The outer enclosure of the fuel cell is typically made of steel or aluminium. This provides the first line of defence against damage. The enclosure encases a bladder, which is made of a rubber and Kevlar composite. This bladder is coated in an elastomer-coated aramid material, which is a requirement by the current FIA standards. The bladder is designed to be flexible and have high burst strength. The bladder also has a foam baffling inside, which prevents fuel from sloshing around and causing weight balance and distribution issues.
Fuel cells with a high alcohol content, such as E85, require a different bladder and foam material. Alcohol and water are particularly damaging to the bladder, so it is important to drain the cell after every event if running an alcohol-bearing fuel.
Fuel cells are available in a range of sizes, from 3 gallons to 32 gallons.
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Installation
Installing a fuel cell in your race car is a complex process that requires careful planning and execution. Here is a step-by-step guide to help you through the installation process:
Prepare the Car:
- Disconnect the fuel filler hose from the fuel cell.
- Remove the seat from the car, following the specific instructions for your seat model. For example, if you have a ButlerBuilt Seat, refer to the installation guide provided by the manufacturer.
- Undo all the fasteners holding the fuel cell cover in place using the appropriate tools, such as a nut driver, wrench, socket, ratchet, or impact driver. There are usually four sets of fasteners on the two sides, top, and bottom rows.
- If necessary, use a pry bar or a blunt flat-blade screwdriver to remove the fuel cell cover.
Clean and Prepare the Fuel Cell:
- With the fuel cell out of the car, clean any old residue or debris that has collected over time.
- Protect the new fuel cell from sharp elements that could rub against it during driving, such as rivet heads and sheet metal edges, by using tape.
- If your fuel cell comes with foam, cut it to fit the surge box in place to reduce fuel movement during cornering, braking, and acceleration.
Install the Fuel Cell:
- Install the internal vent line, ensuring the hose is not kinked or blocked. This is crucial for proper tank venting and fuel loading.
- Use a new gasket and replace the fuel cell cover plate, threading the fasteners loosely in place.
- Ensure all plastic washers are in place to prevent leaks.
- Mark the fittings for identification, such as "V" for Vent and "R" for Return.
- If you have an external fuel pump and are upgrading to an internal fuel pump, refer to the manufacturer's instructions before proceeding.
Reassemble and Test:
- Reinstall the fasteners, ensuring they are properly torqued to the specified tightness.
- Reposition the fuel cell cover and reinstall the seat.
- Test the fuel cell and ensure there are no leaks.
Additional Considerations:
- If you are racing, ensure your fuel cell has a bladder for safety.
- Consider the size and shape of the fuel cell and whether it needs to comply with racing regulations.
- Choose a reputable manufacturer, such as ATL, for safety fuel cells that meet or exceed crash resistance specifications.
- Always prioritize driver safety when installing and using a fuel cell in a race car.
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Fuel types
Fuel cells in race cars are designed to meet the demanding needs of race cars and high-horsepower vehicles. They are a high-performance alternative to modifying stock gas tanks, providing a direct, efficient solution for fuel delivery challenges. Racing fuel cells are pivotal for vehicles pushing the limits on the track. They offer enhanced safety, performance, and the ability to feed high-capacity fuel pumps. The fuel cell tank and pump work together to replace conventional fuel tanks, offering a more efficient and reliable fuel delivery system.
Racing fuel cells are available in various shapes and sizes and are made from different materials, such as high-strength plastic or steel with internal bladders. The material strength and inner design of automotive racing fuel cells help to protect drivers in crashes by preventing fuel spillage.
Racing fuel cells can accommodate various fuel types, including gasoline, diesel, alcohol, and E85. The type of fuel used depends on the specific requirements and regulations of the race.
It is important to note that fuel cells in race cars are subject to strict safety standards, such as those set by the FIA (Fédération Internationale de l'Automobile). These standards ensure that the fuel cells are properly designed, inspected, and certified to maintain the safety of the drivers and the vehicle.
Additionally, proper maintenance of the fuel cells is crucial. This includes regular inspections for cracks or delamination and draining the cell completely before off-season storage. For fuel cells using alcohol-bearing fuel, it is recommended to drain the cell immediately after every event.
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Frequently asked questions
A race car fuel cell is a reinforced gas tank that is usually boxy and mounted inside a vehicle. It is often placed in a protected area, such as the truck of a race car, to prevent damage in the event of a crash.
Race car fuel cells provide safety and performance advantages over factory-original gas tanks. Their material strength and inner design help to prevent fuel spillage during crashes and optimise fuel delivery in racing and off-road conditions.
Race car fuel cells typically have a lifespan of 5 years, with the option for manufacturers to recertify and extend their use for up to 2 additional years, resulting in a total maximum lifespan of 7 years.
