Leaking Fuel Cell

[slomove]

After 3 years of no problem use my Fuel Safe cell (the MSI Birkin special version) started leaking. Just a dribble out of the small bottom (vent) holes when rocking the car. Today I took it out and removed the cell bulkheads and all the foam but the bladder appears to be intact. I was actually surprised that after I pumped out all fuel with the installed fuel pump I still could pour out about a gallon that the pickup can not get to (actually a pretty smart quart size box in the middle of the tank bottom with ball check valves to 3 sides to prevent fuel surge). That is wasting about 15% tank capacity.

Barring the still existing possibility of a bladder leak somewhere I suspect the rubber/cork gasket on one of the bulkheads gave up. Some of them really looked tattered. I will check with Fuel Safe tomorrow what to do (really annoying with the PNW2007 tour coming up in 5 weeks).

Main reason to post that long story here: did somebody see something like that happening with a Fuel Safe cell and if so what was it?

Thanks,

Gert

[11Budlite]

Hi Gert,

Sorry I can't help you because I'm still about 1-2 weeks from putting fuel in mine, but I'll be interested to see what you find.

Bruce

[slomove]

I checked with Fuel Safe but they can not help me rebuilding the cell in the short term. Totally overwhelmed with military equipment orders for Iraq.... But then, I understand that has higher priority than fixing my weekend toy.

So, I removed the frayed gaskets, cut new ones from rubberized cork gasket sheet (Autozone) and installed that with additional Permatex non-hardening fuel resistant gasket maker (horrible messy stuff). Then I plugged all openings, pressurized the cell as hard as my lungs allowed and dunked the entire cell into a trash bin full of water. I should have done that before taking everything apart for comparison but too late.

The cell was still leaking small air bubbles from 3 of the flange bolts and the nylon washer of the fuel pickup connector. I think this is a weak point in the design of the cell. If the nut for this bulkhead AN6 connector is not tight the washer/gasket may turn and/or leak. If it is too tight the nylon washer squeezes out and it also leaks. For now I just used generous amounts of the gasket maker goop around the leaking bolts, the bulkhead washer and the flange and hope it will hold up. Next water test is tomorrow.

I also found out why there was so much fuel left after the pump was sucking air: The pickup nozzle in the surge pot was installed to the higher rear of the tank. I turned it forward 180 degrees, thus lowering the intake about an inch. I hope that should be good for almost another gallon of usable tank capacity.

Gert

[solder_guy]

... pressurized the cell as hard as my lungs allowed and dunked the entire cell into a trash bin full of water. ...

Gert:


I hope that your experiments go well with the cell! I like your test methods! :iagree:

Rob