Why you should NOT use fuel cell foam in a fuel tank
10-07-07, 06:40 AM
#1
Why you should NOT use fuel cell foam in a fuel tank
Last year I had issues with the baffles coming loose inside my fuel tank. In fact the loose baffle took out the vapor check valve on the passenger side of the tank. Since a new tank was $450, I figured I'd try removing the baffling and stuffing the tank with fuel cell foam instead. Problem 1 became immediately apparent - nothing I did could keep the foam from jamming the fuel level float assembly.
But problem 2 was much worse:
It turns out the sloshing of the fuel and remaining edges of tank baffle will shred the foam, causing bits of foam to clog the fuel pump sock and fuel filter. Thankfully my engine got through it all OK, which is almost surprising considering that this problem originally appeared as bucking at the exit of high-G corners, which of course is under heavy engine load. At first it seemed like I lost track of my fuel level, because topping off the tank solved the problem, but as the filter became more clogged then the real issue became obvious.
Last night I drained the old tank, poured the fuel thru a coffee filter in the funnel to catch the foam, and poured that back into the new tank. Painstaking, considering I last drove the car with a nearly full tank to get home without the engine dying on me.
Verdict: for broken tank baffles, buy a new tank or empty your current tank, lower it, and use JB weld to reattach the baffle where it's come loose from the tank wall.
Dave
But problem 2 was much worse:
It turns out the sloshing of the fuel and remaining edges of tank baffle will shred the foam, causing bits of foam to clog the fuel pump sock and fuel filter. Thankfully my engine got through it all OK, which is almost surprising considering that this problem originally appeared as bucking at the exit of high-G corners, which of course is under heavy engine load. At first it seemed like I lost track of my fuel level, because topping off the tank solved the problem, but as the filter became more clogged then the real issue became obvious.
Last night I drained the old tank, poured the fuel thru a coffee filter in the funnel to catch the foam, and poured that back into the new tank. Painstaking, considering I last drove the car with a nearly full tank to get home without the engine dying on me.
Verdict: for broken tank baffles, buy a new tank or empty your current tank, lower it, and use JB weld to reattach the baffle where it's come loose from the tank wall.
Dave
10-08-07, 05:36 AM
#4
Rotary Freak
Sounds like you are not going to persist with the foam, a common fix when using a production foam filled tank in a track setting over here is a VDO float in column fuel level sensor.
Uncertain how much work will be required to fit it in a FD though....and it retails for about $A200 as well.
Uncertain how much work will be required to fit it in a FD though....and it retails for about $A200 as well.
10-08-07, 05:53 AM
#5
Well I think if you were to stuff the tank TIGHT with foam, and use an electronic fuel level sensor, it should work ok.
But it has to be stuffed tight, since the foam gets gushy and shifty once wetted. The edges of broken out baffle will most certainly be an issue. I think it would be necessary to remove the tank, clean it, and grind those edges smooth. I had considered an electronic gauge, ($150+) but the filter started clogging before that.
Dave
But it has to be stuffed tight, since the foam gets gushy and shifty once wetted. The edges of broken out baffle will most certainly be an issue. I think it would be necessary to remove the tank, clean it, and grind those edges smooth. I had considered an electronic gauge, ($150+) but the filter started clogging before that.
Dave
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