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Updated - 06/09/2005

Fuel Cell Installation - Part 2

•  ATL - Sportsman Fuel Cell

  • 8 Gallon capacity

  • Internal Surge Tank

Start plumbing...

• We used 2" exhaust pipe, with 45 degree bends to create the silver 'S' section connecting the original fuel filler tube to the fuel cell inlet. 

• Weld them together, test for leaks, (remember these will not be pressurized), then paint 'em.

• Attach each end with 2" rubber, (gas line rated) flex tube.

• Run 7/16" supply line from fuel cell to fuel pump intake. (hard to find this size gas line rated, but it's out there.)

• Run 3/8" return line from original return line to fuel cell.  (not shown, but the original return and new return are joined by a brass union)

• Run 3/8" vent line back up to original vent location on fuel filler neck.

• Fabricated new fuel filler tube cover, and mount to original filler location.
• Covered large area on drivers side with single sheet, slides under original deck, goes to bar next to fuel cell.
• Not visable, but the frame at the back of the car, is about 1" lower than the frame rails coming from the wheel wells.  The bulkhead material was cut about 2" longer in the back, and a couple of 45 degree bends brings it down to the back frame, and is easy to attach.

• The passenger side is made in two pieces, it made it easier to get a tight fit around the filler tube.
• First piece slides under original deck, and sits on right side frame rail.
• The second piece, goes over the first, but slide under the original deck, and wraps around the fill tube.
• There are two screws thru the original deck attaching it near the fill tube, and a few more attaching it to the first piece.

• Fabricate cover for fill tube.  Start with the sides, then add the top. 
• Attach to bulkhead and filler tube cover.
• The end.