I've got the back end of the car disassembled right now, awaiting an AP2 rear subframe, diff upgrade, and a few other goodies. One of my other offseason upgrade objectives is to address fuel starvation issues, and drop additional weight off the car. I'm thinking I will either: modify the gas tank to allow running with less than 1 gallon, or spring for a small (5-8 gallon) fuel cell with an in-tank trap-door surge tank. The stock tank with pump assembly weighed right at 21lbs, so I know I'm not going to be saving much, if any, weight with the cell itself. The car is not street legal, sees mostly autocross use, with occasional track days. Eventually, I might try hillclimbs or timetrials, but for the short term future, it's just an autocross car.

I've seen posts detailing bits and pieces of the various solutions, but I'm left with a few questions:

* If I modify the stock tank, how do I re-plumb everything up without the evap system?

* If I do the fuel cell, are there any solutions that allow retaining the stock fuel lines, or am I going to need to run new ones?

* What is an appropriate size/type fuel line to run for the feed and return? Do they need to be hard lines, etc?

* Are there any gotchas that I should be aware of with a cell?

Thanks!

 

We had our OEM tank modified.

They cut open the tank and welded in a full surge tank with check valves.

It allows for preservation of OEM fuel gauge and pump assembly.

 

For a fuel cell, you need to cut away a portion of body metal above the gas tank to make a square fitment area for the cell. I'm not sure what people have done as far as gauges, but I'd guess aftermarket.

If you had some confidence in your engineering an external surge tank would work, too.

 

I just finished installing a fuel surge tank on my returnless MY06 for about $600. You can get fittings to plug into the OEM fuel fittings for a plug-n-play install.

Let me know if you need specific information. In a nutshell you need: external fuel pump, FPR, surge tank & hoses.