X180 ESPRIT TURBO FUEL TANKS-DIY - Page 2 - LotusTalk - The Lotus Cars Community
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post #21 of 59 (permalink) Old 12-12-2014, 05:23 PM Thread Starter
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The old, hard (petrified) fill hoses need not be re-used, they wont seal at the joints.
Fortunately, 21 Century science gave us many excellent choices.
Larger hose can be obtained inexpensively from Amazon. Always verify your tanks inlet OD and hose ID with the seller. I fitted Gates # 23976 Filler Neck Hose on my car. Beware: later cars have a different inlet OD-s!

The smaller, 1" ID hose is Goodyear #38049.

Tanks will receive a layer of thermal blanket to keep the fuel cool.
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Last edited by MRDANGERUS; 12-19-2014 at 05:08 PM.
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post #22 of 59 (permalink) Old 12-19-2014, 05:35 PM Thread Starter
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After thorough research I decided to use "PRODEX" TOTAL INSULATION Foil-Foam-Foil (FfmF) Insulation for both tanks.
It is light weight and has high R value.
(Flame Spread Index/Class: "A" - Class 1 0-ASTM E-84, Smoke Index/Class: "A" - Class 1 15-ASTM E-84, R. Value: 14.5-ASTM C-236.)
Tape used over the seams is Nashua aluminum foil tape, PN#681975B, 11-mil thick and has a butyl rubber adhesive to form an air-tight and liquid-resistant bond for secure sealing.

Looking at them, they remind me the Lunar Landing Module... and I have two of them, LOL.

Grounding brackets were replaced by solid blocks with 3/8" stainless heli-coils. They were epoxy-ied with tanks in place, to assure proper bolt location, and then, welded securely to the tank walls.
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post #23 of 59 (permalink) Old 12-29-2014, 06:27 PM Thread Starter
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Right tank has been fastened in place, fits tight height-wise.

To make life easier in the future, 3 double strand shielded wires were pulled trough the emergency brake cable hole in the bulkhead.
With the tank in place it would be a mission impossible.
One of them will activate the fuel flap latch actuator (trough a relay).
The other two will lay dormant waiting for some mods in the future.

Word about the wires.
8 or 12 pair cable can be obtained from eBay.
Search for "Rapco Horizon Snake 8 pair cable". Individual wires are stamped with a number for easy identification. They are 24 GA, so they are just a signal wires.
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post #24 of 59 (permalink) Old 02-10-2015, 09:18 PM Thread Starter
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Both tanks are in and well fastened in place.
Total weight savings over the old steel tanks=14lbs with 23.5 gal capacity and built-in strainer.
Insulation cost me 4lbs.
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post #25 of 59 (permalink) Old 03-24-2015, 08:50 AM Thread Starter
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Additional comment:

If you incorporate Porsche strainer, the bottom of the sump has to be moved "up" (shallow-er) by 1.5-2" for the outlet hose to clear the bottom of the well.
Original tank has a 90 degree pipe welded into the bottom whilst the Porsche strainer nipple is facing straight down forcing the hose to make 90 deg turn.
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post #26 of 59 (permalink) Old 04-03-2015, 07:57 AM Thread Starter
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post #27 of 59 (permalink) Old 04-03-2015, 08:55 AM
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Wow. Impressive work, far beyond my skill.

2016 Chevy Cruze, manual
1987 Lotus Esprit Turbo HCi
2005 Elise
1981 DeLorean, manual, EFI conversion
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post #28 of 59 (permalink) Old 05-12-2015, 08:59 AM Thread Starter
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post #29 of 59 (permalink) Old 09-28-2015, 07:19 AM Thread Starter
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X-car balance tube has been replaced with stainless. OE steel tube was very rusty.
High corrosion resistant aluminum 5052 or 5068 would also work well in this application.
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post #30 of 59 (permalink) Old 10-14-2015, 09:45 PM Thread Starter
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New SAE J30R6 rubber hoses are much easier to fit if you use a dab of the red rubber grease. Double clamp for reliable sealing.
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post #31 of 59 (permalink) Old 01-12-2016, 10:19 AM
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The thought of this process makes me ill
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post #32 of 59 (permalink) Old 01-12-2016, 09:26 PM Thread Starter
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Yes, it is very traumatic. PTSD to the cube. Crucible of no choice!
LOL
But, once you force yourself to start, it goes much better.

Bonus: you can replace old parts and fix all FUBAR-s in one swoop.

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post #33 of 59 (permalink) Old 01-30-2016, 08:28 AM Thread Starter
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post #34 of 59 (permalink) Old 01-31-2016, 09:14 PM Thread Starter
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Petrified rubber S-hoses are too hard to re-use and seal off. Replaced with 1.05" OD 5086-H32 aluminum pipes and rubber joiners.
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post #35 of 59 (permalink) Old 04-09-2016, 06:32 AM Thread Starter
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post #36 of 59 (permalink) Old 04-09-2016, 07:17 PM Thread Starter
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Stainless cross balance pipe and two aluminum "Z" pipes connect both tanks.
Old rubber connecting pieces became so hard that they could not seal the joints.
There is not much space available in the pump compartment, thus the aluminum pipe was a natural choice.
In comparison, the left side looks "empty".
.
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post #37 of 59 (permalink) Old 05-03-2016, 05:53 AM Thread Starter
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The best way to control fuel sloshing inside aluminum tanks is adding a tall honeycomb substrate at the bottom. There is a 6" thick HC available on the market.
eBay item number:
161765573038
Can not use this method in steel tanks (unless you fit a steel honeycomb).

Usually "quartering" the tank cavity with baffles works good, but if you're missing full horizontal baffle you have to add anti-slosh countermeasures.

NEVER USE any copper, brass or bronze in direct contact with Aluminum=risk of corrosion
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post #38 of 59 (permalink) Old 05-03-2016, 11:19 AM
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I'm currently working on the tanks and with refurbishing the old ones, I guess there is no way to baffle them.

I'm going to use Caswell Epoxy Sealer for the insides. I have used this many times on Motorcycles; steel and plastic tanks as well as my '67 Mini project tank. I have been very happy with the performance.

Jonboy

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post #39 of 59 (permalink) Old 07-18-2016, 11:41 AM Thread Starter
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Quote:
Originally Posted by Jcslocum View Post
I'm currently working on the tanks and with refurbishing the old ones, I guess there is no way to baffle them.

I'm going to use Caswell Epoxy Sealer for the insides. I have used this many times on Motorcycles; steel and plastic tanks as well as my '67 Mini project tank. I have been very happy with the performance.
Jon,
If your tanks are not gone too far (no pinholes), Caswell is a pretty good choice.
I don't know what product Re-Nu is using, but it is not "permanent".
Ethanol mix makes it much more corrosive.
Friend of mine re-nu-ed his MG tank and after 2 years he started pulling flakes of epoxy (?) from the tank.
Finally he duplicated tank in aluminum=no more problems.
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post #40 of 59 (permalink) Old 07-19-2016, 08:03 AM Thread Starter
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