The Fuel Tank Kit from Texas...
The Fuel Tank Kit from Texas Mustang Parts (PN E7RR-00009002-K; $229.95) includes a brand-new reproduction Mustang EFI fuel tank with the stock 15.6-gallon capacity, two tank-mounting straps, a fuel-level sending unit with mounting ring and gasket, and the filler pipe seal. You'll need one more lock ring for the fuel pump mounting as well, also available from Texas Mustang Parts.
Our Factory Five Roadster project has been moving along nicely. We hit a few bumps in the road, but nothing to put us behind our schedule to have the car done by the end of 2006 (it's only mid-August as I write this). Checking the forums at www.ffcobra.com, there are builds in many stages. Some owners have a Mk II chassis still in the build phase and going on three years, but we've also seen Mk III builds purchased after ours that are already running and driving and ready for paint. Much of this progress depends upon your budget, availability to work on the project, and so on. The busy show season has put a dent in our available work time, but we're trying to get out in the garage at least once a week (especially to keep our Web diary fresh).
This month, we're concentrating on our project's fuel system. As we've stated in previous installments, much of FFR's build design hinges around using parts from the immensely popular '87-'04 Mustang, including many parts of the fuel system. The fuel tank itself, the fuel filler neck, the fuel pump, and so forth comes from the donor (if using one) or is purchased new through your favorite Mustang parts vendor. Whether you decide to run EFI of some sort or go with the classic carburetor, you'll still need a Mustang gas tank (or an aftermarket fuel cell designed for the Mustang). The FFR comes with coils of steel line for your EFI fuel system to make the donor-engine swap and fuel-system connections easy. If going carbureted, FFR has a carbureted fuel kit it can provide as well.
Since our Smeding Performance 427 Windsor stroker will need plenty of fuel, we opted for larger 3/8-inch fuel lines by using -6 fuel lines from Mr. Gasket. The -6 lines and fittings allow for an easy custom fuel-line routing solution, and connect easily to our aftermarket Mass-Flo EFI system. We're still using a stock Mustang fuel tank, which we scored through Texas Mustang Parts, and an in-tank fuel pump but with larger fuel lines. With our fuel system complete, we'll detail and drop in our drivetrain next month. Then it's on to the wiring phase.
The late-model Mustang fuel...
The late-model Mustang fuel tank uses a vent valve to release tank pressure to an emissions canister, which is then usually pulled back into the engine and burned via a canister-purge solenoid and a length of vacuum hose. We will not use the canister purge setup, but we'll still need to vent the gas tank. The seal is PN F6TC-9B076-AA and the vent valve is E7DZ-9B593-A, both of which are available from your nearest Ford dealer.
To begin prepping the tank...
To begin prepping the tank for installation, the filler pipe seal was installed first. The seal is a tight fit (understandably so) to the tank as well as the filler neck itself. A light coating of assembly grease or other spray lubricant helps. Just be sure to not push the seal too hard and have it fall into the tank.
The fuel-level sending unit...
The fuel-level sending unit is retained just like one from a classic Mustang or other Ford, with a square-cut O-ring seal and a lock ring. Again, a small amount of assembly grease here will hold the O-ring in place while seating the sending unit. We always recommend a brass punch or a block of wood for loosening or tightening the lock ring on a fuel tank to prevent sparks, but since this is a brand-new tank with no fuel in it, a standard punch will work fine.
Many people are now building...
Many people are now building their FFR Roadsters with aftermarket gauges instead of the factory gauges from a possible donor Mustang. Whether they are the classic-looking gauges or something more modern, you'll need to know the ohm rating of the sending unit at full and empty. We tested ours with an ohmmeter before installation and wrote the numbers on the sending unit for when we wire up our gauges later.
Since we're using the stock...
Since we're using the stock EFI Mustang fuel tank in our Roadster build, an in-tank mounted fuel pump is an easy choice for our fuel-pump needs. There are dozens of fuel-pump offerings available, and they will all do the job. With that said, we opted for a new 255-liter-per-hour fuel pump from Mallory (PN 4258FI; $190).
The fuel-pump installation...
The fuel-pump installation into the tank is probably the trickiest part of the entire fuel system. The tank has a baffled area in which the pump sits. Due to the S-shape of the pump bracket, the pump requires a fair amount of rotating and "clocking" as it is lowered through the hole. It will take a couple of tries, but you'll know when you have it sitting right.