After playing the mixing game for too long I decided I would like to try out a fuel cell and just run straight corn in it. I looked at a lot of options and moving the battery or doing a trunk cell but with small kids in the car I did not want fuel in the cabin. So here we go. This is as budget friendly as I could make it while still making it reliable. This is kinda complicated so I suggest going through the install instructions a few times and just walking through it in your head.
I will say the first impressions and the fitment of the fuel cell are top notch. It took some time to install but was pretty easy. Not a ton of work is needed to get it into place and the CS instructions are great.
Parts Needed
This is a great way to mount the pump and pre-filter . The included stuff above will allow you to do it this way. You will need to make your own sort of metal plate but if you got this far you can figure that out. The fuel pump has to be under the tank as it is gravity fed. Picture courtesy of CorkSport
Wiring is pretty neat all things considered. I was able to mount the relay to the horn bracket. I also grounded the LED there. The rest of the grounds go to a factory point behind and above the cell.
Feed line coming from pump to post filter.
Return line goes to brass fitting and you can see the feed line as well.
I know this pic is a jumbled mess but you get the idea. I marked the fuel lines and labeled it.
I mounted the vacuum block under there, I will be getting a different bolt that will sit flatter as it will hit the hood seal otherwise.
And this is where the cell gets filled.
Yeah so this is a decent amount of work, planning and thinking but if you stick with it you can do it. If you are like WTF I just wanna go fast, buy their kit. Thanks to @CorkSport - Derrick for all the help
I will say the first impressions and the fitment of the fuel cell are top notch. It took some time to install but was pretty easy. Not a ton of work is needed to get it into place and the CS instructions are great.
Parts Needed
- Fuel Cell - CorkSport Mazdaspeed 3 Fender Mounted Auxiliary Fuel Cell
- Corksport has great instructions to help understand how to do all this. My setup differs a little but is very similar. HERE - https://corksport.com/support/instructions/AXL-6-912-WEB.pdf
- Thread Sealant - This works great, stop using teflon tape it's annoying - Permatex 59214 High Temperature Thread Sealant, 6 ml Tube, Pack of 1 , White
- Fuel Line E85 safe - Gates 27349 Barricade Fuel Injection Hose-15' Length, Inner Diameter 3/8"
- This hose is used by a lot of OEM's and is easy to work with and full e85 safe.
- Fuel Pump - QFS-606FT-0806-CV Quantum Performance 380LPH Inline External E85 Compatible Fuel Pump + 8AN Inlet / 6AN Outlet with Check Valve
- You could do 10an for the feed from the tank but I didn't think it was necessary. You also don't need a check valve which I found out would not fit where I was mounting things anyways.
- I have called these guys for support a few times and they have been very helpful and easy to work with.
- If you accidently buy one with a check valve you will need this fitting. Stainless Steel Male Flare AN6 To Male Metric Thread Straight Fuel Fitting Pipe Adapter, -6 AN to M12 x 1.5
- Make sure your Aluminum crush washers are centered, mine were not and it leaked at the pump input and output, maybe I got the wrong size washers but I got it to work.
- Dewhel fuel pump mount mounting bracket clamp cradle For BOSCH 044 Black - I only needed this to mount the fuel pump , you don't need one for the pre-filter if you mount it like CS and I did.
- Filters
- Pre Filter "filters fuel from the tank to the pump" - EVIL ENERGY Inline Fuel Filter 6AN 8AN 10AN Adapter 100 Micron Universal 50MM
- Post Filter "filters fuel from the pump to the rail and return" - Billet Aluminum Inline Fuel/Gas/Petrol Filter+Bracket Cleanable 30 Micron for AN6 AN8 AN10 Black
- If your filters do not come with arrows on them, this will help, take one side off and look for the spring
-
- Pressure Regulator - This is really up to you, there are plenty of ways to do this. Some people mount it to the rail, I was never a fan of that. You can see how mine is mounted in the pics below. Aeromotive 13129 - Aeromotive Universal Bypass Regulators
- Fittings
- 2 @ ICT Billet Straight 10AN Orb to 3/8" Hose Barb Fitting Adapter 10AN to 3/8"
- These are for the post filter, you could use AN fittings but I had rubber hose.
- Black Aluminum 90 Degree Elbow -8 AN AN8 Male To 3/8" NPT Male Fitting Adaptor Connector
- This connects the bottom of the fuel cell to the fittings for the Pre-Filter 100 Micron
- Female 6AN AN6 To 3/8" 3/8 inch 9.52mm Barb 90 Degree Swivel Hose Fitting Aluminum Hose Barb Fuel Line Adapter Black Anodized
- For the feed and return lines, one on the FPR return, one on the JMF PI Rail
- 3/8" Fuel Injection Hose Clamps (Pack of 10) 9/16" - 5/8"
- EVIL ENERGY 8AN Female to 8AN Female 90 Degree Swivel Coupler Fitting Adapter Union Aluminium Anodized Black
- EVIL ENERGY 8AN Female to 8AN Female Straight Swivel Coupler Fitting Adapter Union Aluminium Anodized Black
- EVIL ENERGY 8AN Female to 8AN Male Flare 90 Degree Swivel Hose Fitting Adapter Aluminium Anodized Black
- These fittings are used to connect the fuel pump the the 100 Micron pre-filter
- 6 AN Aluminum 150 Degree Swivel Female AN6 9/16 x 18 Thread to barb 3/8" 3/8 inch 9.52mm Push Lock / Push On Barb Hose End
- Fuel out from pump to post-filter
- Joywayus Brass Hose Fitting,90 Degree Elbow,3/8" Barb x 3/8" NPT Male Pipe Water/Fuel/Air(Pack of 2)
- This is used for return to the back side of the fuel cell.
- 2 @ ICT Billet Straight 10AN Orb to 3/8" Hose Barb Fitting Adapter 10AN to 3/8"
- Electronics
- Hobbs Switch - 4-6 psi Honeywell Hobbs Switch with Metripack Connector, factory set at 5psi, plus 2 way metripack 280 sealed connector Kit
- I also wired this to an in-cabin switch that will ground the relay if I want to manually turn the pump on or if the hobbs fails.
- Wire this to ground for the relay so that when you get into boost "6psi" it will ground your relay and turn on your fuel pump
- 86- run to switched battery voltage - 18 awg "I did add a fuse for a spot in the fuse box that was not used but turns on with ignition"
85- run to Hobbs switch "doesn't matter which pin on hobbs" "Ground the other pin to the chassis" You can also run 85 into the cabin with a switch to ground to manually ground if for running the pump without the hobbs tripped.
30- run to fuse and 12awg battery voltage use larger gauge wire here for pump power.
87- run to fuel pump power side 12 awg
- BONUS - I used this Qiilu Wastegate Turbo Boost,5 Fuel Gas Turbo Boost Car Vacuum Block Intake Manifold Fuel Gas Wastegate Turbo Boost
- Relay - Nilight 50044R 5 Pack Waterproof 40/30 AMP Heavy Duty 12 AWG Tinned Copper Wires 5-PIN SPDT Bosch Style 12V
- Various Wires - You will want 12 awg for pump Positive, 14 awg pump Neg "ground", you will want some heat shrink/solder and all the goodies , you can figure it out I believe in you
- MCIGICM 12 AWG Inline Fuse Holder with 30A ATC/ATO Blade Fuse, 5 Pack
- Hobbs Switch - 4-6 psi Honeywell Hobbs Switch with Metripack Connector, factory set at 5psi, plus 2 way metripack 280 sealed connector Kit
This is a great way to mount the pump and pre-filter . The included stuff above will allow you to do it this way. You will need to make your own sort of metal plate but if you got this far you can figure that out. The fuel pump has to be under the tank as it is gravity fed. Picture courtesy of CorkSport
Wiring is pretty neat all things considered. I was able to mount the relay to the horn bracket. I also grounded the LED there. The rest of the grounds go to a factory point behind and above the cell.
Feed line coming from pump to post filter.
Return line goes to brass fitting and you can see the feed line as well.
I know this pic is a jumbled mess but you get the idea. I marked the fuel lines and labeled it.
I mounted the vacuum block under there, I will be getting a different bolt that will sit flatter as it will hit the hood seal otherwise.
And this is where the cell gets filled.
Yeah so this is a decent amount of work, planning and thinking but if you stick with it you can do it. If you are like WTF I just wanna go fast, buy their kit. Thanks to @CorkSport - Derrick for all the help
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