IMPORTANT INFORMATION FROM FUEL SAFE RACING FUEL CELLS FOR
CUSTOMER CONTAINER HISTORIC AND VINTAGE RACE CARS
1. REPLACING AN OLD OR DETERIORATED FUEL BLADDER
- Modern fuel bladder materials are much tougher and less flexible than the old “bag tanks”. Replacement bladders of FIA FT-3 or FT-3.5 construction may not conform exactly to your container or fuel cell “bay”. Sometimes, these new bladders end up an “approximation” of the original geometry, so a little volume may be lost.
- If you are sending Fuel Safe an old bladder or tank as a pattern, be sure to clean it thoroughly inside and out before shipping. Package it well to avoid dents, punctures or other damage. FUEL SAFE WILL NOT BE RESPONSIBLE FOR SHIPPING DAMAGE. IF YOU DESIRE INSURANCE ON YOUR RETURNED EQUIPMENT YOU MUST LET US KNOW THE AMOUNT TO INSURE AND THE METHOD OF SHIPPING.
- To comply with FIA, NASCAR, SCCA etc., metallic fittings and nut-ring flanges must be used. FIA allows some flex-necks and rubber cross-overs if they are made from fuel bladder material. These are not quite as pliable or clampable as the old soft rubber tube connections.
- It may not be feasible to install modern fittings, necks, flanges etc. in precisely the same location as on the old bladder. However, FUEL SAFE will make every effort to locate these ports as close as possible to the original orientation. Please try to cluster your fittings (fill, vent, return, outlets etc.) on the same plate rather than scattering them over the surface of the bladder. Clustering is neater, cheaper and safer!
- It is sometimes difficult to secure accurate dimensions from an old fuel bladder or tank! Fuel Safe always attempts to accurately reproduce the old bladder or tank, however this is an inexact science and variations are inevitable. If you must have an absolute fit with no deviations, then it will be necessary for the customer to provide a precise build-drawing.
2. FITTING A NEW FUEL SAFE FUEL BLADDER INTO YOUR CONTAINER
- Please read all of Section 1.
- If Fuel Safe is asked to modify a customer’s gas tank or container it will be done on a best effort basis. While we conscientiously maintain good workshop practices, mistakes and inaccuracies can happen. Fuel Safe will not be responsible for damage to the customer’s hardware. Where applicable the customer should consider doing his own modifications.
- Adapting a bladder to an existing aluminum or steel gas tank requires removing the original tank fittings, baffles, fill tubes etc. and boring the tank wall so that the bladder fittings can protrude through. Also, a tank access hole is necessary through which to install the bladder. Interior tank surfaces must be smooth, clean and continuous to prevent abrading the rubber bladder.
- As in paragraph 1) d), it may be necessary to orient fittings somewhat differently, from original, i.e. fill necks can not be located over the edge or corner of a fuel bladder. If the original fill neck is large enough, it may be possible to locate the FUEL SAFE bladder fill pipe inside and under the old “Monza” cap.
- Upon completion, your original tank will now function as a “container” for the bladder to facilitate mounting in the car. Most likely, the old tank will not be a sealed vessel as the bladder fittings will project through the tank’s wall.
3. BUILDING A NEW ALUMINUM CONTAINER IN LIEU OF AN OLD GAS TANK
- Constructing a metal “can” or “container” specifically to receive a bladder is preferable to adapting a bladder to the original gas tank. Containers can be supplied by the customer, or by FUEL SAFE if a drawing is provided.
- The fabricated container may take on a new shape or duplicate the old tank’s configuration.
- The fabricated container should be of at least .063” aluminum and designed with a removable top, bottom or side to install the foam-filled bladder.
- All interior surfaces of the container should be clean, smooth and continuous to avoid bladder abrasions.
- Flanges and fittings should not be located closer than 1” from any edge or corner of the container. All fittings should enter and exit from the bladder’s top surface if possible.
- Larger containers may require external reinforcements or bracketing to support the fuel load and to provide a rigid mounting to the race car frame. Consult your race preparation shop on all matters of structural adequacy.
4. GENERAL INFORMATION
- a. In order of preference, FUEL SAFE can accept any of these inputs to aid in reproducing a fuel bladder:
- (i) CAD solid model (SAT, IGES or DWG) of the finished bladder and fittings
- (ii) CAD solid model (SAT, IGES or DWG) of the finished container and fittings
- (iii) CAD solid model showing interior surface of cavity or metal tank
- (iv) CAD wire frame (DXF) drawing of (i), (ii) or (iii)
- (v) Mechanical drawing of bladder with accurate dimensions, angles, and fitting locations
- (vi) Hand sketch or drawing depicting all dimensions, angles and fitting locations
- (vii) The original bladder if reasonably complete. Old bladders can shrink and deform. So they may no longer be an ideal fit in the cavity. You should check the fit of the bladder carefully to insure proper fit.
- (viii) New container approximating original tank and including one removable access panel for bladder insertion. An extra charge may be levied to CAD model the container.
- (ix) Original gas tank, cleaned, baffles removed and with access panel for bladder insertion. An extra charge may be levied to CAD model the tank.
- b. A specification is also helpful in defining the finished fuel cell product:
- (i) Type of bladder material (see FUEL SAFE Sales Engineer)
- (ii) Foam baffling requirements
- (iii) Internal surge tanks, vanes, sumps, weirs, trap doors, baffles etc.
- (iv) Fuel pick-up(s) size and location
- (v) Accessories such as return lines, level gauges, dip sticks, fuel strainers, fuel pumps, electrical connectors etc.
- (vi) Quick-fill valves, vent valves, dry-break refueling equipment, pressure-vacuum relief etc. (vii) Stenciling or markings such as part #, team name, tech data, capacity, safety warnings etc.
- c. When ordering, these conditions apply:
- (i) Prepayment or a 50% deposit is required with each custom order.
- (ii) Shipment is by Fed X ground unless another carrier is requested. The insurance on customer supplied parts is the customer’s responsibility; Fuel Safe normally ships all parts uninsured. Fuel Safe will not be held responsible shipping damage.
I have read and agree with the above terms.
Customer’s signature: ____________________________________________