Assembly Instructions
Frequently Asked Questions
What is the average useful life of a Fuel Cell Bladder?
How long is Foam good for? How do I tell if my Safety Baffling Foam needs replacing?
Torque Specifications
Torque Specifications
Screw Size | Max Torque (in-LBS)
1/4-28 | 70
10-32 | 25
8-32 | 15
6-32 | 10
M6 | 70
M5 | 40
M4 | 20
Critical Safety Notice — Read Before Beginning
Proper alignment, correct torque, safe handling, and mandatory pressure testing are essential for a successful assembly and long-term fuel cell performance. The issues below represent the most common causes of leaks, premature wear, or component damage:
- Misalignment: Ensure nut ring, gaskets, can lid, and fill plate remain perfectly concentric. Even a slight offset can compromise sealing surfaces.
- Over/Under-Torque: Follow all inch-pound torque values exactly. Incorrect torque can deform hardware, damage gaskets, or cause leaks.
- Wiring Considerations: Confirm routing and polarity of wires for sending units or accessories. Avoid pinching wires during assembly.
- Pressure Testing (Required): The fuel cell must be pressure tested before adding fuel to confirm sealing integrity.
Pressure Testing Requirements:
- Do NOT exceed 1 PSI during pressure testing
- Never add fuel before a successful pressure test is completed
- This product is not ready for use until a quality review confirms a successful pressure test
Skipping or improperly performing any of the above steps can result in fuel leaks, fire risk, or damage to surrounding components. Review these requirements carefully before proceeding.
This video has chapters that enable you to jump to specific sections for instruction.
Tools Required
The following tools are required to complete assembly and pressure testing:
Torque Tools:
- Inch-pound torque wrench (capable of 40–150 in-lb)
- Backing wrench (required when torquing AN fittings to prevent fitting or plate rotation)
Wrenches / Sockets:
- 7/16" wrench or socket (perimeter and flange hardware)
- 11/16" wrench (-6 AN fittings)
- 7/8" wrench (-8 AN fittings)
Measuring & Cutting:
- Measuring tape or ruler
- Razor blade or hose cutter (for fuel pickup hose)
Pressure Testing Equipment:
- Regulated air source
- Pressure gauge (0–5 PSI recommended)
- Soap-and-water solution (leak detection)
Alignment & Prep:
- 1/4-28 all-thread studs (for nut ring alignment)
- Clean microfiber cloth
- Camera or mobile device (to document foam orientation)
Technical Note: Using the correct tools — especially a calibrated inch-pound torque wrench, accurate measuring tools, and a regulated low-pressure air source — is critical for proper sealing, correct hose length, and safe assembly.
Assembly Instructions
Unpack & Verify Components
Technical Note: Verifying all components before beginning prevents mid-assembly delays and ensures compatibility with your specific kit.
- Unbox the RTA kit.
- Inventory all included and optional components.
- Inspect the bladder/cell to ensure everything arrived in proper condition.
Remove Foam Baffling
Technical Note: Correct foam orientation ensures the fuel pickup performs consistently under acceleration, braking, and cornering loads.
- Carefully remove the foam from the fuel cell.
2. Carefully record the exact orientation of each foam block — correct reinstallation is critical for proper fuel pickup performance.
Pro Tip: Photograph the foam before removal for easy reference during reinstallation.
Tools: Camera or mobile device (for documenting foam orientation)
Measure & Cut Pickup Hose
Technical Note: Proper hose routing and length are critical to preventing fuel starvation during vehicle dynamics.
- Determine pickup routing (center rear or right rear based on your application).
- Measure hose length from beneath the foam to ensure proper pickup depth.
Prepare Pickup Assembly
Technical Note: Correct assembly of fittings and internal filters ensures optimal flow and prevents cavitation or clogging.
- Install the AN fitting into the fuel pickup hose.
- Slide the required hose clamp(s) over the hose prior to inserting the fitting.
- Fully seat the hose onto the fitting barb.
- Position hose clamp(s) over the barb area and tighten securely.
Caution: Hose clamps must be properly positioned and fully tightened to prevent pickup separation or air ingestion.
- Insert the fuel filter into the hose, ensuring correct orientation.
- Secure the pickup assembly to the foam using a zip tie.
Pro Tip: This step is easily overlooked — measuring from under the foam ensures the pickup sits at the correct depth and prevents fuel starvation.
Tools: Measuring tape or ruler; razor blade or hose cutter
Clean Fuel Cell Interior
Technical Note: Debris inside the bladder can obstruct fuel pickup components or damage pump systems downstream.
- Remove all foreign debris from inside the bladder.
- Recommended: use clean water and a microfiber cloth for a residue free wipe.
Tools: Clean microfiber cloth
Reinstall Foam Baffling
Technical Note: Reinstalling foam accurately maintains internal baffling performance and ensures consistent fuel delivery.
- Reinstall the foam in the exact orientation noted earlier.
Pro Tip: Reference the photo taken during foam removal to confirm correct orientation before proceeding. This helps prevent subtle misplacement that can impact fuel pickup performance.
Install Nut Ring & First Gasket
Install Nut Ring
Technical Note: The nut ring establishes the primary sealing plane; improper installation can compromise the entire stack‑up.
- Position the nut ring inside the bladder.
- Align the nut ring bolt holes with the bladder flange.
- Use 1/4‑28 all‑thread studs to maintain alignment during assembly.
Caution: Misaligned hardware can damage the bladder flange and lead to sealing issues.
Tools: 1/4‑28 all‑thread studs; 7/16" wrench or socket as needed.
Install First Gasket
Technical Note: Gasket alignment ensures uniform compression when torquing hardware, preventing leaks and uneven wear.
- Slide the first gasket over the studs and seat it evenly on the bladder flange.
Install Fill Plate & Pickup Hose
Technical Note: Fill plate orientation affects serviceability, hose routing, and overall system ergonomics.
- Orient the fill plate (part# XXX) based on system layout and desired fitting orientation.
- Attach the fuel pickup hose to the underside of the fill plate using the appropriate AN fitting (-6 AN or -8 AN, part# XXX).
Caution: Torque the AN fitting to the specified 150 in-lb — do not under or overtighten. Proper torque is critical for sealing and longterm reliability.
Tools: Inch-pound torque wrench; backing wrench; 11/16" wrench for -6 AN or 7/8" wrench for -8 AN
Bolt Assembly (Star Pattern)
Technical Note: Torquing in a star pattern distributes load evenly, preventing flange distortion and gasket failure.
- Starting at a stud location, install bolt (part# XXX) and washer (part# XXX) hardware and hand tighten around the perimeter.
- Torque all perimeter bolts to 70 in lb in a star pattern.
Caution: Confirm threads are fully seated before torquing to avoid bolt or flange damage.
- Remove all thread studs.
Pro Tip: Removing studs after the first torque pass reduces the chance of shifting components.
- Install remaining bolt (part# XXX) and washer (part# XXX) hardware and torque to 70 inlb.
- Tools: Inchpound torque wrench; 7/16" wrench or socket.
Install Fill Neck & Outer Flange
Install Fill Neck
Technical Note: Proper fill neck installation ensures secure coupling with external fill hardware and prevents leaks during filling.
- Position the fill neck gasket (part# XXX) on the fill plate.
- Install the fill neck (part# XXX) over the gasket, insert alignment studs, and hand start bolts (part# XXX).
- Torque bolts to 70 inlb.
- Tools: Inch pound torque wrench; 7/16" wrench or socket.
Install Outer Flange Hardware
Technical Note: The outer flange hardware supports the final sealing compression and must be torqued evenly to maintain integrity.
- Install outer flange bolts (part# XXX) around the outer flange.
- Torque bolts to 40 inlb.
- Tools: Inch pound torque wrench; 7/16" wrench or socket.
Pressure Testing (Required)
1. Seal all outlets, fittings, and ports as required for pressure testing.
2. Apply regulated air pressure to the fuel cell.
Maximum test pressure: 1 PSI — Do NOT exceed
3. Apply a soap-and-water solution to all sealing surfaces, fittings, and bolt interfaces.
4. Inspect for air bubbles indicating leaks.
Caution: Do not exceed 1 PSI. Excess pressure can damage the bladder or sealing components.
If Leaks Are Observed:
- Slowly release pressure.
- Verify fastener torque values and star-pattern sequence.
- Confirm gasket alignment and seating.
- Retorque fasteners as required using specified torque values.
- Repeat the pressure test.
Successful Test Criteria:
- No bubbles observed during inspection
- Stable pressure maintained throughout test duration
- No audible air loss
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