GTV-S2000 (warning not for the Alfa purist)

[sh0rtlife]

looks great

still got room to get a spare in and out?

[Keven]

Thanks!! Yep, plenty of room to get the spare in and
out. I'm going to add some split foam pipe insulation
around the edges to keep from stuff banging on the
somewhat sharp fuel tank edges.

Any suggestions as to what adhesive to use for this?

[cowfy]

that gorilla glue seems to glue anthing to anything.

[Keven]

Installed the fuel fill hose. It's marine quality (abrasion resistant,
and fire proof), 1.5" diameter. Only problem is the routing, the
hose dips below the fill neck of the tank. Will this be a problem
while filling?

[sh0rtlife]

its iffy....but id bet that yes it will be a problem...any chance of taking that neck you had made and putting a 45 deg elbow in it to correct the angle?...if nothing else your going to have fuel pooling in the hose wich wont be good

might also want to consider coating the inside of that tank to prevent future leaks and rust

[Trav]

I know from experience that type of hose can be bent really hard with out problems. You could install a hanger and lift it up to eliminate the sag. Nice project!

[Keven]

Plumbing the fuel system! I cut the stock quick connect
Honda fuel fittings off the fuel pump assembly, then
drilled into the plastic and threaded with 1/4 NPT tap.
A 90deg NPT to 6AN fitting was then threaded into the pump
assembly. I then installed some 6AN bulk head fittings
to run to 3/8 aluminum tube. I added some 3/8 foam
pipe insulation over the aluminum tubes to protect them
from any debris while driving. I will be attaching these
with some insulated clamps. The flex lines in the trunk are
6AN teflon stainless braided with Earls quick connectors.
So next I will plumb in a filter in the engine compartment
and make the flex lines to the fuel rail.

I will post more pics of all this soon...

[rafael]

Keven,

Why did you move the petrol tank from the original position? Safety?

[Keven]

Rafael,

The main reason was to be able to use the S2000 fuel tank
with the integrated fuel pump. I also thought that the fuel
tank over the axle would handle better. But if you read some
of the post on that subject, there is some debate as to wether
this is true. Safety was also a consideration as the Alfa
tank does seem really vulnearable right next to the rear end.
Now there is still not much metal between my tank layout and
the Alfa (especially if you dont use the rear bumper). But I
am planning a roll cage, and a "bumper bar" in the trunk for
a little more gas tank protection.

[Keven]

Here are some more pics of the fuel system plumbing.
The fuel pump assembly pic shows the cut off Honda
quick fittings laying on the tank, and the NPT to 6AN
fitting screwed into the pump assembly.

The other pics are of the Earls quick connect 6AN
connectors and stainless hose.

[pastaman86]

I just skimmed through most of this thread and I have to say that is a damn impressive conversion you got going there!

[Keven]

Pastaman, thanks!

Some more fuel plumbing pics...
I had the rear filler funnel changed have a 45deg hose
outlet, so the angle is ever so slightly negative towards the
tank. Some fuel may accumulate there, but not mutch.
I also added a 1/4" nipple for the vapor return from the tank
to the fuel fill tunnel. Can you spot it in the pics?

The S2000 tank had a very compicated vapor recovery
system that actually dipped into the tank. I removed this,
and welded a piece of metal with a drilled and tapped
hole for a 1/4" nipple that runs the vapor hose to the
tank to the fuel funnel. The Monza cap I have is vented
al-la "old school".

The stock S2000 fuel return in the tank had a nozzle that
directed fuel over the pump. I am assuming this was for
cooling the fuel pump when the fuel level is low, and the
pump is not submerged? Not to leave this to chance I
took the nozzle that was drilled off the stock pump, and
glued it to the Earls fitting using JB Weld. I look up the
properties of JB Weld, and their website claims that it
is impervious to petroleum products, acid, and most chemicals.
I hope this includes gasoline!

The lines under the car are covered in 1/8 foam tube covers
to protect from rocks, etc. They are attached to the body
using Earles stainless rigid line clamps.

[Keven]

The intake on the motor uses a Russel fitting made specifically
for Honda's with fuel pulse dampener (Its the white cap over
the fuel inlet). I made a 6AN stainless line with Earls fittings that
connect to a Russel 40um fuel filter. I also made a custom
aluminum bracket to hold the filter to the Alfa body. After
the filter I have a special male to female Earls 6AN adaptor
that has a 1/8NPT port to add a fuel pressure guage. I thought
this could come in handy if I ever needed to trouble shoot
the fuel system. I then run the flex line to the fuel rail, and
secure it with some zip ties, and a rubber bushing to prevent
any damage to the other vacumn line. There is also a filter
in the tank in the fuel pump housing, as well as a "pillow"
filter at the fuel pump inlet.

The return (no pic) runs from the fuel rail to the 3/8" aluminum
rigid line that has a 6AN to 1/4" barb (this is how the S2000
had this line, so I figured it was ok for me to use).

I still need to connect the rigid line to the fuel filter and tie
it all down with Earls clamps. More to follow...

[sh0rtlife]

ive used jbweld in the past to seal fuel tank leaks...15+ years later and that tank still doesnt leak...just dont use that JB"quick" crap it doesnt hold .....i see you opted for the 45deg bend in the fill like i sugjested..looks like it was ment to be that way now and "should" keep ya out of issue ...whats this "oldschool" vented setup you speak of?

[pastaman86]

Keven: just noticed you live pretty damn close to where I'm from. Nice!