924Board.org

[ZODIAC]

i suspect rust in my tank(rust is visible in the filter and PO said he thought the tank had rust inside). i am thiking of just installing a 10-15 gallon fuel cell, but wanted to see if anyone had done this on their car.

example

are there any drawbacks?
if i get one with a fuel sending unit would it be compatable with the stock guage?
any other concerns?

i am going for a race inspired look with the car in the long-run(simplified dash, flat vynil covered door panels center, console deleted) and think this would add to style and function.
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"Kraut cars, they know how to build 'em".
1977 924 N/A - Red with waterdamage interior
yes...waterdamage is now a color...

[924RACR]

Major PITA and expense. Won't go any faster. I haven't bothered. Cheaper and easier to run stock, just pull it and clean or replace it.

I've also heard of heavily-oxygenated fuels doing ugly things to the foam in the cell...
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Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

[PORSCHEV]

[ZODIAC]

i know it wont go any faster with a fuel cell. i did not take into account the fuel deteriorating the foam. i actually had no clue about that at all. is this like a "over a ling time" kind of thing, or a couple of years?

i'm just throwing around options for getting something brand new back there. the plan with this was to replace the whole fuel system to function better with the carb setup.
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"Kraut cars, they know how to build 'em".
1977 924 N/A - Red with waterdamage interior
yes...waterdamage is now a color...

[PORSCHEV]

I have a carb on my 327 hooked into the factory tank on my 76. The tank will flow any size carb you can trow at it.

I just eliminated the electric pump and run the mechanical one on the engine.

Better off just cleaning or replacing the factory tank IMO.
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1976 924
5 lug conversion, 17'C2 wheels,custom body work,327 vette engine.

1978-#53 "D" track racer.

[ideola]

Here's JR Mock's fuel cell install:
http://www.jrmock.com/fuel_cell_install_1.htm

Here's mine:
http://www.924board.org/viewtopic.php?p=237391#237391

To do this, you pretty much have to cut out part or all of the rear deck floor and also the spare tire well. You then also have to fabricate a cage to protect it. My cage is modeled after JR's, but note that mine is oriented a bit differently. This is the other consideration: my arrangement will ONLY work in a car with a G16 or G31 gearbox; the Audi gearbox is too long, so you have to go with a setup like JR's if you have an Audi box.

If you're not going to race, you can get by with one of the non-FIA-approved cells, which will save significant money on the cell itself. Also, you do not have to run with the foam in the cell if you're not going to race. I will not be using foam in mine due to the corrosive nature of E85. But you will want a surge tank of some sort (effectively provides the same function as the fuel accumulators on the CIS setup).

The other cost factor will be setting up the filler neck, an expense I did not incur on mine, since I am planning to just open the hatch, and have a trap door in the bulkhead that will replace the deck floor I cut out. On a street car, you'll probably want a conventional filler setup, which will add to the cost of the materials. If you or a friend can weld, you can probably get a non-FIA setup purchased and installed for ~$1K.
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erstwhile owner of just about every 924 variant ever made

[fiat22turbo]

The foam is replaceable. They're just blocks of foam. I would talk to the cell manufacturer about the type of fuel you'll be running and their foam. Filling is simple as long as you can connect to the stock filler neck. Many mount them in the trunk and fill them via the trunk. Of course most sanctioning bodies require a firewall between the tank and the passenger compartment, which means trunk mounted cells get a sealed box built around the top with a sealed flap to access the filler neck.

For the sender, I don't know what range the 924 uses but I seem to remeber that there are typically two types of ranges available that can work for most gauges.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[ZODIAC]

thanks for all the comebacks. i dont plan on racing rhe car, just going race inspired from a design standpoint. i've installed a fuel cell in a probe before for mini-stock, so i figured on cutting someof the deck up.

i will be the only driver of this car once it finally gets going, and i have no problem with poping the hatch to fuel her up. and (granted i havent checked) but i have a G16, i know it's a dogleg. but i should have the spaceto do it like yours ideola. i dont however see is how you get the 1K figure? the tanks i am looking at are between $138-250. i guess fuel lines, low pressure fuel pump, square stock for the cell's cage, new fuel filter, fittings and sheet metal. it could get up there.

wht about degree of difficulty? i have a dremel, angle grinder and limited access to a mig welder(the Coast Guard academy an hour away rents them out), but i can only do that with an extension cord in the back yard.
_________________
"Kraut cars, they know how to build 'em".
1977 924 N/A - Red with waterdamage interior
yes...waterdamage is now a color...

[fiat22turbo]

Ideola probably paid someone to install it for him, makes sense if you're unsure since it isn't something to half-ass, especially if racing.

Sounds like you'll be able to install it just fine, worst case you can get the frame tacked in place well enough to get the car over to a more powerful welder.

I concur on the surge tank in the cell.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[ZODIAC]

[quote="fiat22turbo"]worst case you can get the frame tacked in place well enough to get the car over to a more powerful welder.quote]

yeah, my wifes uncle has a mig and a tig. plus he is really good with welding and fabrication.

so basically, if i go without foam and with a surge tank in the cell. i could follow ideolas/JR Mock's method, and still a) clear the trans, b) still have a quasi-useable hatch area and c) have a more reliable fuel system(everything will be new once i am complete)

damn this car just gets more expesive the more i dream about what it could be!
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"Kraut cars, they know how to build 'em".
1977 924 N/A - Red with waterdamage interior
yes...waterdamage is now a color...

[ideola]

I had a friend do the fabrication work. By the time you purchase metal stock (IIRC, I purchased two 24' sections of 1" square tube and a 4x8 sheet of 1/8" steel), saw blades for cutting it up, cut off wheels and flap wheels, a propane torch for heating up and removing the undercoating, a tank of gas and a spool of wire, your fuel cell and all the ancilliaries, and then float a few dollars to a friend to do the work...you see where this is going. I borrowed a welder from my neighbor, so if you don't have free access to one like I did, you also need to factor in rental cost.

There are a number of areas where you could cut costs. I removed the entire rear deck floor. Todd didn't like the idea of welding directly to the frame rail, and also wanted to strengthen the rear area, so a lot of the 48' feet of square tube went into that. I don't recall the exact measurements, but without doing this extra strengthening, you could probably get by with one 24' section. I've also barely touched the 4x8 sheet, but it will be used for other stuff, and it was cheaper to buy it in a whole piece than pre-cut.

I paid a lot more for my cell to get one that was FIA certified and also specially prepped for E85. I did not pay "union scale" for the fabrication work, but Todd was happy with what I paid him. He refused to set a price, so I paid him what I could afford. His work and the quality of it was worth more than what I could afford.
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erstwhile owner of just about every 924 variant ever made