Fuel Cell 101 

Very interesting! Thumbs up for insisting on a roll over valve and not just for rolling over. As a dealer tech for decades, the roll over valve is part of the vent system because , filling the tank, fuel rich air exists the tank to allow liquid fuel in. Most OEM, like GM & others, use a liquid floating type. When liquid fuel reaches it, it lifts and spring assisted but seals. This action pushes raw fuel fuel up the filler neck and shuts off the pumping action when it reaches the aspirator tube inside the nozzle. There are wires from the pumps nozzle for ground and shut off inside the rubber hose. If the “Ball” does not float or goes to a simple gas line up the roll cage, makes a “U” turn then terminates, the smell of gas will fill the garage as it expands and contracts. Using an activated carbon canister will capture these organic hydrocarbons. It creates a mild exothermic reaction. Once using or pulling the fuel level down, it will allow air in, endothermic reaction, and keeps the tank for collapsing in a vacuum. Canister are sized by the fuel tank. Get a used one from a GM truck in the bone yard and glue some cube of foam (Seat Upholstery Foam) to the canisters “Vent” pipe. Or, attach a hose and place a lawnmower fuel filter on the end. Purge fitting can be plugged unless you program the PCM to purge. No purge cold, idle or upon deceleration as injectors shut off. The roll over valve is connected to “Tank” fitting. The only time “Vent” & “Purge” is closed during “EVAP” testing for leaks. We don’t want hydrocarbons escaping and running off to have fun by the pool or watching the game! Hell No! Hide the canister? Run roll over valve line up high, loop down, go under the bed or somewhere to mount. The return line (If used) but returns normally to the bucket where the pump is. The bucket type are call modular resivour assembly or MRA. To avoid aerating the fuel, dropping volume which in turn drop volume and misfire. That is a no, no in the car world. They actually had the misfire counter less sensitive in 1997. On many models, the output high pressure side had a “Tee” in this line. They placed a Venturi valve made of brass, cast into the plastic. It had a 0.030” hole and bell shaped. It creates a low pressure in a passage to the bottom filter. This pulled fuel into the bucket, cooled the pump and kept a supply of fuel at the ready. They had a float that lifted to open a dump to maintain the the level of fuel inside the bucket. Fuel pumps are designed with two rotors where the first one pump fuel in and had bleed holes to allow air out. The second rotor creates the volume. Without volume, you have low pressure. It passes thru the center of the pump, out the top, pass a check valve to hold fuel in the lines while the regulator blocks off return when pressure drops as shut off. Just some info. ASE Master Tech since 1978 - Retired

All the Bleepin Jeep guys need their own minion thumbnail to show who is gonna be in the video. I lost my shit when I first saw yours

Wow! I didn't know anything about fuel cells before watching this. Your videos are gold! Keep them coming!

thanks for the update and informative post. Crawler is coming together nicely. Cant wait to see it in action, hell of a job thanks for sharing.

That thumbnail!!!! So good. Thanks for the info too, looking to install a fuel cell soon.

best intro ever!!!! actually laughed out loud

That cover pic is killer LOL

I been following this build pretty good. It's pretty interesting.

I can really appreciate how much time that took tig welding. definitely worth it, turned out awesome?

Skill n patient..skill n soul...how awesome??!??

God I love tig welding, one of my favorite things to do. Awesome fuel cell man!

Matt, the minion thumbnail is the BEST. I spit my drink out when I saw it...hahaha.

Where did you get the attachment so you can use the stock fuel pump?

Amazing video

awesome video

Good information. Thanks!!!

Matt, you should also include that in case someone was to build/design their own fuel cell to keep in mind as to what type of sending system they are going to use. as it is not uncommon for someone to use the stock unit. however on some vehicles the return line us not only used to return fuel and displace pressure, it is also used to cool the electric fuel pump.

awsome job mat godbless

Man that's badass! That's fukkn cool that you made that!!

A lot of information. Thanks

Definitely helpful feel more confident putting an aftermarket cell in my wj

I don't know why but the minion yous creep me the hell out haha

he makes welding tig look so easy!

Anyone know where I can find one of those weld on jeep tj fuel pump rings?

Could you help me out with sourcing the aluminum ring with threads to mount the pump? I can't find one to save my life

you should check out the holley hydra mat... that will eliminate the need for the sump in the tank

Great video! What brand and model mig welder and plasma do you have? Also, keep the xj blue!

thats great! plus you wont be using the gas as much going down hill, i need too practice some aluminum welding

Ever heard of an hho welding rig?

Hey Matt where did you get that weld on ring for your fuel pump at

Where did you get your threaded aftermarket ring for the fuel cell?

my dad's jeep had foam in the tank and it took up so much of the tank it only held a few gallons

Where can I find that ball valve?

weld it when the fuel is in, that is the real chalange

Aluminum is definitely my favorite metal to tig

love the minion haha

Where did you get the ring for the fuel pump ?

You fooled me with the title! Interesting, nevertheless! :-)

The description disclaimer hahahaha

Just came across some vids about running engines on gasoline vapour, it may be something you would be interested in looking into further for this project or on a future one. Would greatly increase your MPG and allow you to run for hours on just a small amount of gasoline. 2 videos here of engines running : ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-RNUfryhT4H8.html ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-MsFRaV4zKEQ.html Great videos buddy, keep them coming!

If there is no bladder,foam or baffles it is a gas tank.

Anyone can weld a tank, you forgot the main part on installing it and connecting everything

that is not true, the fuel cell foam last way longer then a year, all the technology came from the aircraft industry , and small aircraft fuel cells and foam last a very long time the idea is that a real fuel cell has the bladder that will bend and squish in the event of a serious accident. the foam is used to stop sloshing and to slow down leakage in the event of a rip in the cell. anything else with out a bladder or foam is just a gas tank not a fuel cell. this is from fuel safe... Fuel Safe Fuel Cell Guidelines Here at Fuel Safe Systems, we work tirelessly to provide the highest level of quality, performance and durability. Everything we manufacture is built to withstand the extreme demands our customers place on our products. Safety fuel cells are out of sight so they tend to be forgotten. Fuel cells have a finite life span. The environment can greatly affect the cell’s longevity. The typical lifespan of a fuel cell is between 8 and 10 years, although all sanctioning bodies limit use to 5 years from the date of manufacture. By following a few simple guidelines and inspecting your fuel cell on a regular basis, you can ensure that the performance and safety of your vehicle will remain intact. •Avoid fuel additives •Do not store fuel in the cell for long periods •Do not expose the cell to harsh chemicals •Do not use solvents on the cell •Store your bladder in a cool dry place, out of direct sunlight •Inspect the interior and exterior of your cell once a year

hahahaha i pity the foo cell!

The minion in the thumbnail is creepy af :)

RAR…random ass rotor

the way you sey "vehicle" annoys me

fu·el cellnounnoun: fuel cell; plural noun: fuel cellsa cell producing an electric current directly from a chemical reaction You have a gas tank, not a fuel cell