Building a fuel cell

[karolko]

I am planning on building a custom fuel cell that resides exactly where the factory fuel cell typically sits.

It will be built out of aluminum but i am still fuzzy on some things:

1) what gauge aluminum should i use
2) 5052 or 6061? or something else?
3) how should i make the baffles? i have no idea as to what shape they should be and where the ct outs should be for fuel to move around.
4) where should the return line go into the fuel cell? top, side?

Photos would be fantastic!!!


Thanks guys

[turbofabricator]

6061 welds the best. .063"-.080" will work well. The return line should be as far away from the pick-up as possible, and into the top of the tank. You will also need a vent line. (-4AN is more than enough) Baffles are needed to keep the fuel trapped around the pick up during acceleration, braking, and cornering. A baffle can be a simple wall that centers the fuel around the pick up. If you are starting from scratch, build the tank with a rear sump.

[karolko]

i do plan on putting in a rear sump for sure. What i had in mind for baffles were 3-4 vertical walls that had three semi circles cut out of the bottomsto allow fuel to move around. how does that sound???