Gas tank replacement options - fuel cell customization
 

Long story short, my tank is in a mess, got some rust and pin holes. While I'm tempted to try one of the tank restoration kits using POR 15 sealer, I have been looking at fuel cells that can work.

Searching online I found RE-Speed proposed tank. But we all know the story with them.

Then I found the guys in Australia over at PAC Performance were making a direct bolt in 20 gallon tank for almost 2k!!! But the design seemed exactly like the RCI and other tanks on eBay. (Actually a little bigger)

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Here is a pic of the tank unpainted.

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And of course one of the tank fitment.

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So doesn't look like we need any fancy shaped tank. Just one that fits.

I measured under the car yesterday and noticed that a RCI 17 gallon aluminum fuel cell I had my eye on should fit. The fuel cell is 30"x17"x7" and should fit pretty easily. I don't think you can use the factory straps etc. So get the strap kit as well for the fuel cell.

Here is the RCI fuel cell

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Of course like the PAC performance tank you'll need to weld on tabs for mounting so all the weight is not on the straps and you can mount the factory heat shields etc.

RCI has a version with and without a sump. I think I'll be getting the one without the sump as I have an Aeromotive Phanton intank 340lph stealth sump kit. So I'll be using none of the RCI inlet outlet, vent nor refill (may weld them up)

Biggest issue will be the filler neck, which shouldn't cost much to fab up.

What are your thoughts? I'm about to order the fuel cell. Just looking for any input. I searched but only found people cutting the spare wheel well out. And I'm not going to do that.

Forgot the shot from the back showing the PAC tank installed.

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subscribing to get updates. keep us posted on how this works out for you.

Also interested in seeing how this works out for you. Subscribed!

Glad this has sparked some interest as I would like to find a solution.

I have found the tank new online on a few sites for as low as 499. (Atkins has one for 750 and mazdatrix for about 599)

So ~250 for the RCI tank and 50 for the straps and say another 50-100+ to customize it. I'm thinking a new OEM tank would be nice for the peace of mind.

http://www.mazdapartsunlimited.com/oe-mazda/fa6642110a

But the DIY fabricator and boredom too I guess makes me want to persevere a bit more :)

I made the 30x17x7 tank out of cardboard to see if it will fit and will mock up on the car tomorrow hopefully as the car is by the mechanic. Would love to do a side by side comparison but don't have the tank home either.

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From just looking at it it's clearly smaller than the OEM mazda rx7 tank. So I'm 98% positive the RCI aluminum fuel cell will fit without a prob.

Also the filler neck may be in an ok spot as well. They are 45* necks available and I think you can angle it to the right direction for an easy fit. (So add that to the cost)

Decisions decisions.

If you make your own tank, you might want to angle the bottom just slightly and make previsions so that it is deep enough for a sump and slosh tank. This way if someone wanted to go efi, it would make it much easier. You might look at Re-Speeds design and get some inspiration.

Oh, Im using one of these :)

apparently there is only one brand new tank in north america lol

Spoke to the guys at mazda parts unlimited and they said its in Canada and a few weeks out.. so looks like i'll be buying the RCI and customizing it as i can get that almost immediately.

Ok some updates. Have it gotten back the new aluminum tank from being modified (old ports and filler welded up and filler neck added and hole drilled for the Aeromotive stealth intank)

But here is a great side by side of the old rx7 tank and RCI 17 gallon fuel cell

You can see the stock tank is bigger but because of it's custom shape fits more snug under the spare tire.

I was thinking of building the "bump" into the new tank but decided against it. Got the strap kit with the tank and it almost lines up with the car. Will post photos of it fitted this weeken.



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Fits like a glove!!!

Used the straps from the RCI kit, used the two holes from the chassis for the stock tank and had to drill one hole in the spare tire well and another in the trunk area. All stock hear shields fit and bolted up. Welded on a 2" neck for the filler. Will take more pics when I remove to paint this week. Came out awesome!!

Very happy!!

Few more pics. One showing the strap bolted up to the stock strap holes in the chassis.

awesome! so the tank is tilted forwards a bit, right? saw the video of the fuel pump kit u'll be using, looks pretty trick. can't use the stock fuel pump location of the new tank?

Yes it's tilted a bit forward at the moment. The front of the car is currently on the lowest setting on the coilovers so that's not helping. I think when I take off the 18's, put on the 17's level the car with the front AND new rear coilovers it should level off more. And I can adjust it from the rear straps if needed.

The Aeromotive intank is where you can barely see where I scribed to drill the hole. The home you seeing there now was covered/welded up.

The next set of pics will explain allot more.

That thing is awesome! Did you put pictures of this on Facebook? I swore I saw pictures of this earlier today on a group...anyways - nice install.

Yup, I posted this on the first gen rx club on Facebook :)

Haha I thought it looked familiar. Looks like it is a great install and should last forever!

Took the tank out to clean, get painted and Reassembled for the last time.

Great work!

That looks great!

How is the tank working out ?

just came across this post what's the update