Fuel System
The original GT40's had twin 20 gl fuel tanks mounted on each side of the car in the sills. The fuel tanks were an integral part of the car. Like the original, the RCR40 has twin integral fuel tanks but each holds 15 gl of fuel. This enables the cockpit to be wider, accomodating a driver and passenger much more easily.
The tanks on the RCR40 are baffled to reduce sloshing.
The original GT40's used twin Stewart Warner fuel pumps. I wanted to use the same pumps in my desire to replicate the originals. However, they are no longer made and they go for as much as $400 each on eBay.
I am also going with 48IDA Webers for induction. The fuel pumps best suited for Webers, aside from the original SW pumps, are Carter low pressure units. And thats what I went with. Here, I temporarily installed the rear bulkhead mods and the fuel pumps/filters.
Now its time to do the other side...
I decided to do some re-engineering of the fuel pickup. The car comes with a "nipple" welded on top of the fuel tanks with a hole in the center. The customer has to drill the hole through the fuel tank and tap the nipple for a fitting.
The tube fits in the hole and fitting, into the tank for the fuel pickup. I didn't like that design, so I removed the fitting with a grinder. The customer also has to drill a 1-5/8" hole for the fuel level sender.
I originally thought about designing a plate that would mount both the fuel level sender and the fuel pickup (6AN 90deg bulkhead fitting). I made some drawings and even one mockup. It just didn't look right.
After looking at the fuel level sender, I realized the top of the sender would make a great fuel pickup mount. So, I bought two more fuel level senders, trashed everything but the plate, gasket and mounting hardare, drilled out the center to accomodate the bulkhead fitting, and installed it next to the fuel level sender.
Holes marked for the fuel pickup (left) and the fuel level sender (right). This is on the passenger (left) side.
1.625 holes now drilled in the fuel tank. I made a special vacuum hose and removed the metal debris.
I then marked the mounting screw locations, drilled, then tapped the holes for the mounting screws. The fuel level sender is now complete, less wiring.
Here is the fuel pickup unit that I designed and fabricated. Its made from a SN35 fuel level sending unit from Classic Instruments. The sending unit was trashed and the plate retained. I drilled out the center, and added a 6AN bulkhead fitting, a 6AN compression/AN fitting, and some 3/8" aluminum fuel line. You could substitute a straight bulkhead fitting if so desired.
And how it looks in place (not completely instaleld yet)
Here, the rear bulkhead mods are now permanently installed, the fuel pumps and new in-line filters mounted, and the fuel lines fabricated and installed. I wanted to make the fuel lines more like the originals. That meant the braided SSTL lines with the blue and red anodized fittings were out. Instead, I went with Aeroquip Socketless fittings and Aeroquip black nylon fuel line. I think I achieved my goal.
Here is the driver's side along with the reproduction Ford Advanced Vehicles chassis plate...
And the fuel pump regulator...
The kit comes with original style fuel caps. However, they do not (or did not) come with any means to hook up a fuel filler hose to the tank. I made a chassis mockup with some 1/4" stock and installed the fuel cap to it.
I then got out my trusty straight edge, a pencil, some paper, and a compass. I proceeded to design one. I took the drawing to a local machine shop and had them machine two fuel filler flanges from 6061 T-6 aluminum.
The flange is held in place from the bottom with the fuel hose and a clamp. When the fuel cap is closed, the rubber seal locks it in place and seals the fuel system.
The cost to make these two parts was $250. Pretty steep. But I had no choice. I located an off the shelf fuel flange, but the hose size was 2", and Fran's car comes with a 1.5" nipple welded to the tank.
Fuel Vent
To be continued...