Fuel Cell Project
The Bike with Fuel Cell Installed
The author assumes
no responsibility for any of the ideas presented here. Since this
is a private effort and not a business
all ideas, component
locations, and any other information provided here are provided
as a complementary offering only.
Anyone using any
of this information does so at the own risk and liability.
The rack with one cross brace removed
(Note white dots on the tail piece.
These are 1/8" pilot holes drilled from the inside through
the supports for
the original rack (22 litre trunk)
This is the cross member. See the
circles in the square recesses. These get drilled out for the
supports that come up from the tailpiece
Note the two silver vertical supports.
These stabilize the rear rack and can stay in place if the cell
are removed and the original trunk
put in place.
This shot gives you an appreciation
of all of the supports added. The two that hold the cell mounting
plate attach in the
cross brace mounting bolt holes.
You can see one rack to tailpiece suppor in the back.
Note the routing of the fuel line
down to the fuel filter mounted behind the saddlebag rack.
The fuel line then passes through
an existing opening into the under-seat compartment.
Note how the fuel line loops around
to avoid kinking and then heads off to the shutoff valve (next
The shutoff valve is clamped to
the frame and the frame is protected from being scratched by the
From the valve, it heads off to
a 5/16" "T" in the fuel injection return line.
The orange switch in the upper left
is the fuel pump illuminated switch. It actuates a 30amp relay
which operates the pump.
The switch is mounted in a BMW switch
blank which was cut to hold the switch - a very clean install.
- Fuel Cell - Fuel
Safe CT105 - ~$150.00
- Shut off valve 1, 3/4" long MILTON
part number s1094-4 - Air compressor supply. All brass forged
body with plated brass ball, teflon seals, 1/4" turn handle.
- 1/4" NPT to 5/15" Male hose
barb, LASCO part number 17-7715. (these go to the shutoff valve
above) - Any good hardware store
- AN-8 to AN-6 adaptor Earl's part number
989486 - Find a good hot rod shop, preferably one that is serious
about racing. - $9.95
- AN-6 to 5/16" barb 90 degree (slightly
larger that 5/16" but will work). Earl's part number 709106.
- Hot rod shop as above - $16.20
- AN-8 cap part number FCM 3741 (don't know
if this is Earl's or not). - Ditto on the location
- Fuel pump NAPA part # 2P74019 - $29.99
- Fuel filter NAPA part # 3032 - $3.99
- Fuel hose clamps (12) NAPA part # 505-1204
- Brass Tee NAPA Part # 730-2948 - $ 4.49
- Cap (for covering the fuel filter inlet
when the tank is removed NAPA part # 2-645 - $1.42
- 10' fuel line (Fuel injection rated) -
NAPA part # H-205 - $50 - You won't need this much but it's hard
to say how much you will need.