Leak Prevention & Crash Protection

Fuel cells are purpose-built to eliminate weak points that can lead to leaks, ruptures, or fires—especially during collisions.

1. Leak-Proof Structural Design

• AN fittings: Threaded, aerospace-grade connections that hold tight under high fuel pressure.
• Fully welded shell: TIG welding eliminates seams or rivets that might corrode or fail.
• Roll-over vent valve: Seals manually with a secure cap to prevent spills or vapor release during use.

A modern fuel cell gas tank combines reinforced welded construction, internal foam baffling, and sealed AN fittings to create a fuel system that’s leak-proof, explosion-resistant, and purpose-built for performance driving. Compared to traditional plastic tanks, it offers a far safer and more durable solution—especially for high-horsepower builds or track applications.

How a Fuel Cell Gas Tank Works in High-Performance Builds

Fuel Cell vs. OEM Gas Tank – What’s the Difference?

OEM fuel tanks are made for daily driving—not racing or rugged terrain. Most lack features like:

• Surge protection
• Anti-slosh foam
• Reinforced outlets or high-flow fittings

Fuel cells, on the other hand, are purpose-built for demanding use:

• Compact TIG-welded shells fit tight spaces (trunks, rear seat deletes, truck beds)
• Internal foam reduces fuel movement and vapor buildup
• AN fittings enable secure, leak-resistant fuel routing
• Stronger aluminum or steel construction resists rupture

Bottom line: For custom builds, swaps, or racing, a fuel cell offers better safety, flow stability, and modularity.

Controlling Fuel Slosh for Performance and Safety

Hard launches, sharp turns, or steep climbs can cause fuel to slosh violently inside a tank. This leads to:

• Fuel starvation
• Vapor lock
• Pressure spikes
• Even system failure under high G-forces

Fuel cells solve this by including:

• Anti-slosh foam that disperses wave motion
• Crash-resistant design that maintains structural integrity

This ensures reliable fuel delivery under any driving condition.

Fuel Flow Path – From Cell to Engine

In a performance fuel system, each component plays a role in clean, pressurized delivery:

Step-by-step layout:

1. Fuel exits the cell through a large feed port (usually -10AN).
2. Passes through a 100-micron pre-filter to catch large debris.
3. Enters an inline fuel pump for pressurization (ideal for EFI).
4. Flows into a 10-micron post-filter for fine particle filtration.
5. Reaches the fuel pressure regulator, which ensures steady PSI.
6. Excess fuel returns to the tank in a loop, preventing vapor lock and pressure spikes.

Tip: Always mount the fuel pump below the feed outlet. This helps gravity prime the pump, reducing cavitation and wear.

Can a Fuel Cell Be Used for Gasoline or E85?

Yes, you can use E85 – with the Right Setup

Fuel Compatibility and Materials

Gasoline Safe? – Lining and Bladder Options

Yes—but only if the fuel cell is designed for it. Look for:

• Internal bladders or fuel-safe coatings to prevent corrosion
• Ethanol-compatible foam that won’t degrade over time
• Sealed AN fittings and non-rubber gaskets to resist fuel vapor breakdown

Standard aluminum or steel cells without proper linings can corrode or leak over time when used with pump gas.

Using E85, Ethanol, or Methanol – What You Must Know

E85 and alcohol-based fuels are more aggressive than gasoline. They:

• Absorb water, which accelerates corrosion
• Break down traditional fuel foam and seals
• Require non-reactive linings like Teflon, plastic bladders, or hard anodized coatings

📌 Tip: Choose E85-compatible fuel cells with marked ethanol-safe components if your build runs flex-fuel or full alcohol blends.

Corrosion Resistance – Foam & Coating Checklist

For any fuel type, check if your fuel cell uses:

• Closed-cell anti-slosh foam, safe for ethanol/methanol
• Anodized or polymer-coated aluminum walls
• Stainless or PTFE internal fittings
• Bladder-style liners for high-end resistance

Failing to match fuel type with proper internal materials can lead to fuel system failure or safety hazards.

The EVIL ENERGY Fuel Cell Gas Tank is fully compatible with gasoline,E85—just make sure to choose PTFE (Teflon-lined) fuel lines when setting up your system for safe and long-lasting performance.

Best Practices for Safe Gasoline or E85 Use

Venting & Pressure Regulation

• Pressure buildup
• Vapor lock
• Fume accumulation Use rollover vent valves and pressure regulators designed for your fuel type.

Seals, Valves, and Vapor Control

• Use ethanol-rated check valves and O-rings
• Install vapor barriers in trunk-mounted setups
• Maintain proper return lines to relieve system pressure

Fire Prevention Tips for Fuel Cell Installs

• Never mount near heat sources (exhaust, turbo piping)
• Always secure the cell to avoid movement or puncture
• Use braided fuel lines with thermal sleeves where needed

What Fuel Pump Should You Use with a Fuel Cell?

Choosing the right fuel pump is essential for getting consistent performance from your fuel cell. Whether you're building an EFI swap, a high-horsepower drag car, or a reliable off-road rig, your pump setup must match your flow needs, mounting layout, and fuel type.

In-Tank vs. Inline Fuel Pump Systems

When to Choose External Inline Pumps

Inline fuel pumps are mounted outside the tank, typically below the fuel cell’s feed outlet. They’re easy to inspect, replace, and upgrade—ideal for:

• Custom builds with limited in-tank space
• Trunk-mounted fuel cells
• EFI conversions needing high-volume flow
• Swaps where the pump must be relocated (e.g. LS swaps)

Inline pumps are also preferred when you're running:

• Return-style systems
• Dual filters and pressure regulators
• External surge tanks or filters

In-Tank Advantages – Cooling and Noise Reduction

In-tank fuel pumps are immersed in fuel, which provides:

• Natural cooling, helping extend pump life
• Quieter operation, since the tank dampens pump sound

They're often used in OEM-style applications, and can be integrated with aftermarket fuel cells that support internal pump modules or surge tanks. However, they are harder to service and upgrade.

Should You Upgrade to a Fuel Cell? Here’s the Bottom Line

Fuel cells aren’t for everyone—but if you’re building for performance, safety, or layout flexibility, they may be the right move. Here’s how to decide:

A Fuel Cell Is Worth It If You...

You run high-horsepower, boosted, or track-only builds

If your vehicle makes over 500+ HP, uses turbocharging or supercharging, or sees regular track time, a stock gas tank likely won’t keep up. A fuel cell offers better fuel stability, flow control, and fire resistance.

You need custom fuel routing or trunk relocation

Building an LS swap? Running dual pumps? Mounting your tank in the trunk or bed? Fuel cells make it easier to route AN lines, add external components, and optimize space.

You want maximum safety under extreme conditions

With welded construction, anti-slosh foam, and leak-proof fittings, fuel cells dramatically reduce the risk of vapor lock, leaks, or explosion during crashes or high-load operation.

🚫 A Fuel Cell May Not Be Ideal If You...

❌ Drive daily on public roads without emissions certification

Most fuel cells lack EVAP fittings, charcoal canister support, or DOT approval. They’re not street-legal in some areas, especially where emissions testing is required.

❌ Prefer plug-and-play simplicity

Fuel cells often require custom mounting, AN fuel line routing, and electrical wiring. If you’re looking for a bolt-on upgrade, this system may be too complex.

❌ Don’t have space, tools, or time for custom install

Fuel cells typically need cutting, fabrication, or reworking the spare tire well. Without the right tools or workspace, installation can become a barrier.

📌 Tip:

If your build demands reliability, safety, and fuel system precision, and you’re ready for some hands-on work, a fuel cell is one of the smartest upgrades you can make to your high-performance vehicle.

Explore EVIL ENERGY Fuel Cell Kits

Fuel Cell Gas Tank Kits – Multiple Capacities Available

• Capacities: 8 / 10 / 15 / 17 / 19 gallons
• Fitment: Varies by model – compact, mid-size, and V8 RWD platforms
• Recommended for: Universal swap builds, 240SX, Mustang, classic Civics, and other tuner platforms

10-Gallon Fuel Cell Kit

• Compact size for tight installs
• Ideal for drift cars, lightweight track builds, or rear seat delete conversions

19-Gallon Fuel Cell Kit with Level Sender

• Large capacity suitable for street cars and high-displacement platforms
• Includes integrated fuel level sender

❓FAQs

Q1: What is a fuel cell and how does it work?

A fuel cell is a high-performance fuel tank designed for racing, off-road, or modified vehicles. It uses internal foam and AN fittings to safely store and deliver fuel under high load and pressure.

Q2: What is the difference between a fuel cell and a fuel cell gas tank?

In motorsports, the terms are often interchangeable. Unlike OEM gas tanks, fuel cells use stronger materials, internal baffling, and modular fittings for better safety and customization.

Q3: Are fuel cells safer than OEM gas tanks?

Yes. Fuel cells are built with anti-slosh foam, rollover safety valves, and fully welded aluminum shells, offering superior impact resistance and vapor control in racing conditions.

Q4: What are AN fittings and why are they important in a fuel cell system?

AN fittings are aerospace-grade, threaded fuel line connectors. They create leak-proof, high-pressure seals—essential for fuel delivery in performance or boosted applications.

Q5: What is fuel slosh, and how do fuel cells prevent it?

Fuel slosh is the violent movement of liquid fuel during hard braking or cornering. Fuel cells use foam and internal baffles to stabilize fuel flow and reduce the risk of starvation or pressure loss.

Q6: Can a fuel cell be used for gasoline or E85?

Yes, most performance-grade fuel cells—including those from EVIL ENERGY—can safely store gasoline, E85, ethanol, or methanol, as long as the right materials are used throughout the system.

To ensure long-term reliability and fuel compatibility:

• Use PTFE-lined fuel hoses (Teflon) to prevent swelling or degradation from ethanol.
• Verify that all fittings, seals, and foam inside the fuel cell are E85-rated.
• Avoid using standard rubber hoses, which can break down when exposed to ethanol-based fuels.

Tip: EVIL ENERGY Fuel Cell Tanks are E85-compatible, but you must pair them with PTFE fuel lines and E85-safe fittings for optimal performance and safety.

Q7: Do fuel cells come with fuel pumps or do I need to buy one separately?

Most fuel cells are sold without pumps. You’ll need to add an inline or in-tank fuel pump, along with filters and regulators, based on your engine’s fuel requirements.

Q8: How do I choose the right size fuel cell for my car?

• 8–10 gallons: Compact builds, drift cars, race-only setups
• 15–19 gallons: Street cars, turbo builds, long-distance performance use Match your horsepower, available space, and fuel type when selecting.

Q9: Is it legal to use a fuel cell on the street?

Not always. Most fuel cells are not DOT-certified and may lack emissions equipment like EVAP ports or level sensors. Always check your local laws before installation.

Q10: What tools and accessories do I need to install a fuel cell gas tank?

Basic installation typically requires:

• AN fuel lines and fittings
• Fuel filters and pressure regulator
• Mounting brackets or straps
• Wrenches, hose clamps, drill, and sealant