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 Post subject: Adding a fuel Surge tank
PostPosted: June 5, 2014, 11:55 am 
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Joined: April 1, 2010, 10:26 am
Posts: 421
Is soon as I developed a little speed on the AutoX or track days I have been plagued with fuel starvation issues, always having to keep the tank very full was a pain.

My first attempt was to fill the tank with foam, that helped a little but was not even close to solving the problem. So a surge tank was the answer, it's a square tank with check valves on three sides. They come setup for a remote pump, I just made a little bracket to mount my fuel pump inside the tank. I then used foam to hold the tank against the front of the gas tank.

Sounds easy but the first problem is getting the surge tank into the gas tank, it would not go through the stock opening on the top of my RCI gas tank. So I had to cut a larger hole in the top of the tank and use a blanking plate. Cutting the hole was easy, so was getting the surge tank in, the tough part was all the bolts on the blanking plate, I could only just reach inside via the stock filler hole to tighten all the bolts. But I managed to get it done, I also added a perforated stainless pipe so the foam did not block the filler hole and allow my dip stick to still work.

I got all parts from Pegasus Racing, they are real racers and just understand the problems we have, there tech support is great and have got me out of a hole many times. Here is a link to the surge tank https://www.pegasusautoracing.com/produ ... oduct=2538

I also got some foam from http://www.ksrfoam.com/ they do military tank foaming, fighter planes to tank, they sell off cuts at very reasonable prices.

Graham


Attachments:
File comment: All done
CAM00414_zpszkrumj7f.jpg
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File comment: The rest of the foam and the dip stick tube in place
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File comment: Dip stick tube
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CAM00422_zps9mkfivfu.jpg [ 756.67 KiB | Viewed 2915 times ]
File comment: Blanking plate in place
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File comment: Big hole, full on foam
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CAM00418_zpsgulf9t0h.jpg [ 884.84 KiB | Viewed 2915 times ]
File comment: Surge Tank inside gas tank
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File comment: Sure tank outside gas tank
CAM00415_zpsub5qdypl.jpg
CAM00415_zpsub5qdypl.jpg [ 1.74 MiB | Viewed 2915 times ]
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PostPosted: June 5, 2014, 12:49 pm 
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Joined: April 23, 2006, 8:26 pm
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Location: SoCal
$200... I'm sure it works great, but sheez.

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PostPosted: June 5, 2014, 12:51 pm 
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Consider running the fuel returning to the tank (if you do) into the surge tank, else it may get pumped dry when the fuel level is low. The right way is to run that hose in such a way as to not cause bubbles, which can get sucked up by the pump and pushed to the engine.

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PostPosted: June 5, 2014, 8:56 pm 
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Joined: October 19, 2009, 9:36 pm
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Location: meadview arizona
external swerl tank is the best way with the injection pump fed off it and an "in tank" low pressure pump to supply it with fuel.

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PostPosted: June 6, 2014, 8:21 am 
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Joined: September 22, 2005, 8:12 am
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Location: 4AGE in S.E. Michigan
Graham
If you have clearance under the tank I would look at adding a lowered sump for the fuel pump. You can fab a small box for a lot less then $200. I extended the sides of the sump up into the tank for about 4" and added hinges over ports to allow fuel flow into the sump from the sides. DaveW


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PostPosted: June 6, 2014, 9:25 pm 
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Dave, I like your solution, if I ever have to remove the tank I will do exactly that.

KB58, the return line does run down into the tank, it was luck more than judgment, but it worked out that way. It was not cheap, but I only had a few days to make it happen and get it tested before a track day on Monday, so it's going to be worth ever penny if Monday goes by without a hitch.

Graham


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PostPosted: June 6, 2014, 9:59 pm 
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The bottom surge tank is indeed the simplest and cheapest way, but isn't possible if the tank is already as low as possible, which it should be for CG reasons.

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PostPosted: June 7, 2014, 8:46 pm 
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Joined: June 8, 2010, 8:02 pm
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Location: White Rock, BC, Canada
In case it helps someone, I did a post on how to use an OE in-tank pump that has a fuel bucket and a jet pump built in.
viewtopic.php?f=27&t=11744

Not as pretty as the race stuff though :wink:

Hope the track day went well.
Cheers.

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PostPosted: June 10, 2014, 10:46 am 
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The big test was a track day yesterday at Autobahn CC. It worked perfectly so I am very happy. I did run the tank until it started to splutter just to see how low it would go, and there was barely any fuel on the dipstick. So I consider this problem solved. I also had a great time at Autobahn, the weather was perfect, the new LSD, wheels, brakes, light flywheel all work great. The LSD really allowed more corner speed, I was going a lot faster at the end of the day than I had gone in the past. There was another older Caterham (70's or 80's) at the event, another British guy from the Chicago area, it was a race only car, twin cam powered, but he had a transmission issue, stuck in gear. So he went home early and I was not able to get any move info, but a real nice race patina car.

Graham


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