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E30 racing fuel cell information

 
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dale



Joined: 22 Aug 1999
Posts: 3083
Location: Seattle, WA USA

PostPosted: Thu Sep 14, 2006 4:15 pm    Post subject: E30 racing fuel cell information Reply with quote

A guide to building a fuel system for a BMW E30 Pro3 race car.

Written by Dale Beuning dale@unofficialbmw.com
Layout and design of system inspired by Ken Hill and Wes Hill's race cars.

===================================

Notes:
1) All part numbers from Goodridge Catalog, their 1136 line of Swivel aluminum hose fittings for 200 hose

2) For installation of braided stainless steel hose, and available fittings, see this document and these links:
http://www.goodridge.net/
http://www.goodridge.net/webapp/wcs/stores/servlet/category2_-1_64_10551_32018
http://www.goodridge.net/documents/downloads/retail/GoodridgeCat_low.pdf

3) Prices for all these pretty parts is fairly high.

5) North West source is:
Warehouse West
Renton, WA
(206) 772-1910
Talk to Mike Gibson

6) You don't have to use SS Braided line in the trunk, only in the passenger compartment, that makes
it possible to reduce the price of this total project by at least 50%.

6a) You can buy -08 equiv and -06 equiv black rubber high pressure fuel hose at most any auto store,
Carquest is a good bet for this. Use in trunk, under car, and under hood.

6b) You don't have to run SS Braided line through the passenger compartment, you can go through the
floor of the trunk and attach to the stock steel lines at the stock location behind the drivers door under the car.

6c) Ken Hill, Peter Jenkin, Bill Spornitz have all experienced fuel problems with their fuel setups
and are good resources for ideas on troubleshooting your system if you have problems. Usually getting the large element Fram filter before the pump will solve this type of issue.

6d) All of these fittings and measurements for for my Fuel Safe 22 gal cell with -08 supply, -06 return,
and -08 vent fittings. Your cell may be different. If you want to use these exact part numbers
and details, and you haven't bought a cell yet, buy the same one as I have.
But be sure to check that the cell you receive has the same fitting size as I mentioned,
I've looked at 6 fuel cell installs, and it doesn't look like any of them have exactly the
same size fittings on the cell.

7) I used Spectre color hose clamp fittings in a few places on the -06 line, but couldn't make the
-08 ones work, so used normal hose clamps on those. Use all normal clamps to save money.
The BMW OE style with no holes in the clamp are better then the kind you get by default at Schucks/O'Reilly.

===================================

Parts list

All part numbers are from the print Goodridge catalog.
Reference this PDF catalog online for other part numbers for the same fittings.
I used the "136" line of fittings.
http://www.unofficialbmw.com/racing/fuel/goodridge.200.series.stainless.braided.nitrile.hose.and.fittings.pdf

===================================

Fuel Cell

Fuel Safe SM122C http://www.fuelsafe.com
- This is the cell I and several others run.
- Available from Andy Collins at Armadillo
- Online catalog:
http://www.unofficialbmw.com/racing/fuel/fuel_safe_road_racing.pdf
- 22 gallons
- SM122C*** 22 gal. 25 3/4 in. 25 3/4 in. 8 1/2 in.

===================================

08 parts

7ft -08 200 line, 200-08
2x -08 45 1056 (136-4508)
3x -08 Straight hose end 1091 (136-0108)
2x 5/8" diameter hose clamps
1x -08 45 to 3/8 NPT 82245 (AN823-08D)
1x -08 90 1066 (136-9008)
1x -08 pre filter Profession Products 10302 (see below)
1x -08 Tee M-F-M 82453 (CPL-824-0Cool 2x -08 to 1/2" NPT 81645 (AN816-08-0Cool
1x replacement filter element Professional Products 10321 (see below)

===================================

06 parts

33ft -06 200 line, 200-06
2x -06 hose clamps 1/2" diameter 1x -06 Tee M-F-M 82452 (CPL-824-06)
2x -06 to M14x1.5 on filter concave ????
8x -06 straight hose end 1090 (136-0106)
2x -06 45 bulk head fitting 83709 (AN837-06 D)
2x -06 bulkhead nut 92414 (AN924-06 D)

2x copper crush washers M14 for fuel filter input/output
4x copper crush washers M12 for fuel pumps

approx 12x -06 hose clamps or any cushioned 1/2" diameter hose clamp
approx 4x -08 hose clamps or any cushioned 5/8" diameter hose clamp

===================================

Fuel pumps

2x Bosch fuel pumps 0-580-464-021
inlet: M12 straight pipe
outlet: M12 with 1-way check valve, needs banjo fitting, ask Ken Hill
Local Source: call Carquest in Bellevue, likely special order part,
If they need a vehicle application, give them the following:
Mail Order Source:
http://www.pelicanparts.com/catalog/shopcart/911M/POR_911M_FULmot_pg2.htm#item10

Vehicle Application Year OE Ref. No. VM Ref. No. 911 Carrera 3.2 litre 83-89 0 580 464 021 944.608.102.00
Approximate price: $200 each

4x M12xM15.5 copper crush washers:
2x M12 cap nuts for 1way check valve on output of 1way check valve, may be included with pump
http://www.pelicanparts.com/catalog/shopcart/911M/POR_911M_FULmot_pg2.htm#item10

2x M4 nuts
2x M5 nuts
2x M4 crimp connectors
2x M5 crimp connectors



=====================================

Post Pump Fuel Filter : approx $25
Mahle KL22
Application: 1981 Porsche 928 4.4l, (78-83) 911 3.0 SC, 911 3.3 turbo

Height 1 [mm]: 125
Height 2 [mm]: 164
Diameter 1 [mm]: 74,5

http://www.mahle-aftermarket.com/
http://217.6.60.45/mahle/modules/mahleFilter/detail.jsp



=====================================

Pre-pump Fuel Filter : approx $40

Note: alternately use the Fram HPG1 as it has much more capacity to store material before reducing flow. See picture at the end of this post.

In stock at Warehouse West.

Professional Products
Powerflow 10302
(replacement element 10321 : aprox $10)
flows 140 GPH@7psi
flows 360GPH@40psi
filters to 15 microns
1/2"-NPT inlet and outlet ports
http://www.professional-products.com/inlinefilters.html

===========================================================

Assembly order of parts

Vent line
-08 45 1056
-08 16" line
-08 straight hose end 1091
-08 45 to 3/8 NPT 82245
- Moroso aluminum vented catch can 85470, approx $70

Note: the line should go in the bottom, not the side as shown here:


Supply line
Pre-Pump:
-08 90 1066
-08 4" line
-08 45 1056
-08 to 1/2" NTP adapter 81645
Note: use teflon tape on all NTP threads
-08 pre filter Profession Products 10302
-08 to 1/2" NTP adapter 81645
-08 Tee M-F-M 82453

2x -08 Straight hose end 1091
2x -08 22" line
2x -08 hose clamp

Post-Pump:
1x - copper crush washers, lookup size for M12 output of pump, 9077
2x -06 blue hose clamp 8111
2x -06 9" line 2x -06 straight hose end 1090
-06 Tee M-F-M 82452
-06 to M14x1.5 on Mahle filter
(Option: get this fitting in Steel from Fittings Inc. on 4th Ave S in Seattle)
- 14mm copper crush washers 9076
- Mahle KL-22 Fuel Filter M12x1.5 Female input/output, seal with copper washers and teflon tape
- 14mm copper crush washers 9076
-06 to M14x1.5 on filter
(Option: get this fitting in Steel from Fittings Inc. on 4th Ave S in Seattle)
-06 straight hose end 1090
-06 10' line
-06 45 bulk head fitting 83709
- note: use nylon washers for a better fit here and to insulate the fitting from the metal
-06 bulkhead nut 92414
-06 straight hose end 1090
-06 4' line

Return line
-06 45 hose end 1050 - update to 90
-06 11' 6" line
-06 45 bulk head fitting 83709
-06 bulkhead nut 92414
-06 straight hose end 1090
-06 4' 6" line

==========

In June 2006 at PIR, I had troubles with my car cutting out from lack of fuel. I checked my pre-pump filter, it was blocked with gunk from the cell. I cleaned it out and have been driving the car around with a trip permit the last few days, and it got clogged again. I'm going to keep cleaning it and driving it until I can get it to stay clear after a few hours or use.
Be sure to clean the foam from the cell before running fuel through it.
Be sure you don't run any Gasahol or Alchohol fuels through it.

Someone asked me for info on what filter I'm using, here is a link to the unit, its part number 10210.
http://www.professional-products.com/inlinefilters.html

I bought it from Warehouse West in Renton, WA. They would really like you have have the part numbers ready when you come in there, they will sell Retail, but are really a warehouse type of operation.
http://www.warehousewest.net/

Alternate is:
Fram HPG1 to use for the pre-pump filter:

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UnofficialBMW.com Webmaster
dale@unofficialbmw.com


Last edited by dale on Fri May 27, 2011 11:55 pm; edited 10 times in total
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dale



Joined: 22 Aug 1999
Posts: 3083
Location: Seattle, WA USA

PostPosted: Thu Sep 14, 2006 4:27 pm    Post subject: Reply with quote

Guide to fuel cell install:

1) cut out trunk floor, easier if you get someone to do it for you and you have the back end of the car chopped off. We chopped the rear end off to repair damage to that sheet metal, you don't need to do this to install the cell.



2) after floor cut out, looks like this:


3) build a 1x1" tubing box for the fuel cell to mount to, weld to trunk floor over the opening. Drill/tap holes for the cell hold-down bolts in the cell mount:



4) be sure to do a test fit:


5) after paint, looks like this:



6) drop cell in place, unbolt all bolts from lid, push cell into place, re-install all bolts threading them into the frame also, this also shows position of my dual fuel pumps:


7) pic of my completed cell, race ready:



For reference, a picture of Ken Hill's installation, he has a spacer and larger 28gallon bladder installed:


Another approach, ala Greg Miller, use steel lines and bend to fit, much less expensive then stainless steel braided lines:

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dale@unofficialbmw.com


Last edited by dale on Wed Sep 16, 2009 2:35 pm; edited 1 time in total
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cagedruss



Joined: 08 Sep 2004
Posts: 83
Location: Portland, Oregon

PostPosted: Sun Nov 25, 2007 9:14 pm    Post subject: Reply with quote

To save some more money on the fuel lines you can run steel and flare the ends to 37 degree AN to go through the driver's interior and or run the rubber line through a steel or aluminum tube through the driver's interior.
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