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Page 9 - Desining and making custom fuel cell As I mention before, I have to make custom fuell cell. It's going to be small ( cca 10L) but nevertheless, it's going to be very complicated. Problem is because of its miniature size it is going to be hard to include fuel pump with pickup, metal plate with fuel hose fittings, little fuel level indicator (std Yugo 55) and fuel cap with a key that will be placed on the hood. Material of the choice will be ordinary 3mm alu sheet that will be TIG welded when measuring and cutting is done. *NOTE: CLICK ON THUMBNAILS ON THE LEFT TO OPEN LARGER IMAGE !!! (1024X768 PIXELS)*
	I bought Lancia Thema 2.0 16V fuel pump for 20 Euro on italian junkyard.Pump is reservoir-mounted type, which suits my ideas, but in standard form there is a lot of unnecessary plastic & metal things that need to be removed prior instalation.
	... first thing to remove is big plastic fuel pickup, that contains plastic mesh and serves as pump mount.
	...now pump can be finaly seen - it has elastic rubber mount to prevent unwanted vibration. Btw, pump is small, much smaller then I expected, but if that pump can support 2.0 16V engine, it has to support mine too.
	...this is fuel pump inlet - pump has very fine metal mesh that can't be removed and it's integral part of the pump .
	...first cuts on aluminium plate - I draw straight lines with marker, and then cut all plates carefuly with grinder.
	To prevent fuel starvation under acceleration and when going uphill, I create little "valley" where pump inlet will be always (hopefully) in contact with fuel.
	...this is lowest plate and most complicated part to make - there is no much space here and I want to make as large cell as possible..."measure twice, cut once" :-)
	...this is fuel pump position - I need to mount fuel pump on some bracket, so pump can be securily mounted inside...
	...this is side view...
	...another shot ...
	One intersting but stupid problem is how to fill up new fuel cell with gasoline ? After some thinking, I decide to cut complete fuel cap from some car on junkyard, together with key. I was lucky and found perfect thing on junkyard - this is fuel cap from Peugeot 106 - it's round shaped, it has steel bottom that can be welded and it has key ;-)
	...top view of the cap ...
	...it's very good idea to plan fuel hose routing before making complete fuell cell - I'll use hydraulic fittings on all joints (I just hate worm hose clamps) and will try to make most simple and elegant layout possible. Fuel filter will be needed of course - good idea is to use Uno Turbo fuel filter - it has banjo bolt type fittings already so it can be easily attached to other hoses in future.

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