Fuel Safe Systems

Installation & Care

Racing is our passion and Fuel Safe is committed to delivering the highest quality safety fuel cells to our customers.

If you have questions, please call 800-433-6524 or e-mail us at sales@fuelsafe.com. Our sales team is staffed by industry professionals and can assist with any questions you have.

Complete Race Safe Aluminum Fuel Cell

Inspect & Prepare

Install Details

  • 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.
  • Ensure that the fuel cell compartment has adequate ventilation to account for any fuel vapor transfer through the bladder walls. Pockets of fuel vapor can present an ignitable and hazardous condition.
  • Standard fuel cell setups usually include a normally-open vent / rollover valve. Ensure that this vent is plumbed to a location with free-flowing access to open air.
  • Pad or tape the edges of any compartment opening in which the bladder will be installed so as to reduce the possibility of puncture or abrasion damage during installation.
  • Static ground fuel cell fill plate to the vehicle's chassis.

Installation into tight spaces

  • 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. Expand the bladder into all corners of the container once through the access.
  • Check the empty bladder for any signs of Foreign Object Debris (FOD).
  • Reinstall the baffling foam in the reverse order of what was previously recorded.
  • Reinstall the access plate and hardware, using the torque specifications noted below.
  • Check to ensure that there are no fuel leaks during the first filling of the bladder at the access plate location.

Preparation

  • If any cuts or abrasions are seen or occur during installation, DO NOT proceed with installation. Instead, contact Fuel Safe with pictures and information related to how the damage occurred and Fuel Safe representatives will instruct you how to proceed with returning the bladder for repair or replacement.
  • Baby powder can be applied to the external faces of the bladder to reduce friction and while installing the bladder in the housing.
  • Re-torque all screws after receiving the system to ensure nothing has come loose during shipping. See torque values below.

Torque Specifications

Screw Size

MAX TORQUE (IN.-LBS.)

1/4-28

70

10-32

25

8-32

15

6-32

10

M6

20

M5

40

M4

70

Foam Block Kit - Cubes Are Roughly 4" Cubes

Usage Instructions

  • Anti-slosh baffling foam may have debris attached to it from the cutting process. 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.
  • Racing fuel bladder materials degrade faster in high-moisture environments, so ensure that the bladder is not consistently exposed to high-humidity conditions or sitting water.
  • Fuel Safe fuel bladders are approved only for use with hydrocarbon fuels. Neoprene bladders are the only exception and should be used solely with alcohol fuels or water. Fuel additives have not been tested by Fuel Safe and are therefore excluded from Fuel Safe’s limited warranty if damage occurs as a result of their use.
  • When removing anti-slosh baffling foam after use with fuel, spray water on the foam before removal to prevent static ignition of fuel vapors.
  • When not in use, empty the fuel bladder(s) and store in a cool, dry environment.
  • Inspect the baffling foam after two years, and then annually thereafter for any signs of degradation.
  • Periodically check and re-torque the screws on the system to ensure that all components are secured.

Things NOT to do

  • Do NOT attempt to repair a Fuel Safe fuel bladder without consulting Fuel Safe Systems sales representatives.
  • Do NOT weld, drill, cut, or otherwise modify the metal container while the bladder is still installed.
  • Do NOT allow untested fuels or additives to be used in the fuel bladders without prior authorization from Fuel Safe sales representatives.
  • Do NOT pressurize Fuel Safe fuel bladders above 1 psi unless otherwise authorized by Fuel Safe sales representatives.
  • Do NOT expose the fuel bladders to consistent temperatures over 160°F (82°C) over extended periods of time or intermittent temperatures of 180°F (71°C)

Troubleshooting Guide

If you have questions, please call 800-433-6524 or e-mail us at sales@fuelsafe.com. Our sales team is staffed by industry professionals and can assist with any questions you have.

FÉDÉRATION INTERNATIONALE DE I’AUTOMOBILE (FIA) CERTIFICATION

  • Fuel bladders with FIA certification are qualified to race in sanctioned events for a period of up to five (5) years after the manufacturing date noted on the bladder, or to the expiration date shown on the FIA label.
  • After the five-year certification window has closed, fuel bladders can be returned to Fuel Safe for inspection, and if the bladder is still in good working condition, the bladder can be recertified for a period of two (2) additional years.
  • Fuel bladders involved in racing incidents should be inspected by the manufacturer before being used in any other capacity, as the integrity of the fuel bladder may have been compromised during the incident. Information about the incident should be supplied to Fuel Safe to ensure that all safety questions have been accounted for before the bladder is returned to the field.

Warranty

Fuel Safe’s limited warranty can be found at Warranty

For any warranty claims, please provide the following information to a Fuel Safe sales representative:

  • Serial number
  • A description of the problem and photos of the affected areas
  • Information about how the bladder has been used
  • Any information about modifications made to the system, as this will help Fuel Safe troubleshoot the issues

Warranty

Fuel Safe’s limited warranty can be found at Warranty

For any warranty claims, please provide the following information to a Fuel Safe sales representative:

  • Serial number
  • A description of the problem and photos of the affected areas
  • Information about how the bladder has been used
  • Any information about modifications made to the system, as this will help Fuel Safe troubleshoot the issues

Reordering Instructions

Contact a Fuel Safe sales representative at sales@fuelsafe.com with the following information:

  • Serial number
  • Photos of the bladder, including of all internal components (pumps, collectors, filters, etc.)
  • Quantities and required timeline

Fuel Safe may issue a Return Material Authorization (RMA) number and ask you to ship the bladder in if previous design data is not available.

A quote may be provided after either stage in the process, depending on available information.

Reordering Instructions

Contact a Fuel Safe sales representative at sales@fuelsafe.com with the following information:

  • Serial number
  • Photos of the bladder, including of all internal components (pumps, collectors, filters, etc.)
  • Quantities and required timeline

Fuel Safe may issue a Return Material Authorization (RMA) number and ask you to ship the bladder in if previous design data is not available.

A quote may be provided after either stage in the process, depending on available information.

Disposal Instructions

  • Remove all fuel from inside of the bladder (drain or pump out).
  • Remove access plates from bladder and allow all remaining fuel to evaporate.
  • Disassemble the components from the access plates and reuse any desired undamaged hardware.
  • Recycle the aluminum access plates.
  • Drop off the fuel bladder at your local waste disposal site.

Fuel Safe Systems

Aircraft Rubber Manufacturing

dba Fuel Safe Systems
1550 NE Kingwood Ave
Redmond, OR 97756

Tel: (541) 923-6005
Fax: (541) 923-6015
Toll Free: (800) 433-6524
Contact: sales@fuelsafe.com