Racing Fuel Cell & Tank Equipment

What Is a Racing Fuel Cell and How Is It Different From a Gas Tank?

A racing fuel cell is a layered fuel container built for competition use. Most cells combine an outer shell, an inner bladder, and foam baffling that fills the cavity. A stock gas tank is usually a single container shaped to fit one chassis.

That layered design is why racers choose a fuel cell for drag, circle track, and off-road builds. The shell takes the hits, the bladder holds the fuel, and the foam limits how much fuel moves around inside. A stock tank skips those extra layers, which is fine for a daily driver.

If you're starting a fuel cell swap, browse complete cells and replacement parts in Fuel Cells & Components. You'll also want a fuel pump, filter, and lines that match the cell. When you're mapping the entire fuel system, start with Air & Fuel Delivery parts and work outward from the tank.

How to Choose a Fuel Cell Material for Your Build

Choose a fuel cell material based on your mounting space, chassis layout, and how the car is raced. Each shell type changes how the cell is built and mounted, so compare these options first:

• Polyethylene cells use a molded plastic shell, often with walls about 3/16 in. thick.
• Aluminum cells use a fabricated metal shell in place of molded plastic.
• Steel cells add a metal outer container around the bladder or foam-filled core.

Once you've picked a material, check the outlet, vent, and fill locations. Port placement decides how you'll route lines, so it matters as much as the shell. A cell with the outlet in the wrong corner can force awkward plumbing or a new mounting plan.

You can compare cells from RCI fuel cells and RJS Racing Equipment by shell material, shape, and port layout. Measure your trunk, bed, or chassis area before you order. Leave room for straps, lines, and the filler cap.

SFI 28.1 Certification and Fuel Cell Safety Foam

SFI 28.1 is the SFI spec for polymer foam-filled fuel cells. Related specs cover other designs: SFI 28.2 applies to crash-resistant cells, and SFI 28.3 applies to fuel cell bladders. The manufacturer certifies that a product meets the spec, so look for the SFI label on the cell itself.

Safety foam sits inside the cell where you can't see it. It fills the cavity and baffles fuel movement, while taking up only about 1-4% of the cell's volume. That means you give up very little capacity for the added control.

Foam is also a replaceable wear item. JAZ Products offers fuel cells and replacement foam, so you can refresh a cell without replacing the whole unit. Before you mount a new or rebuilt cell, walk through our step-by-step fuel cell installation guide.

Replacement Gas Tanks for Classic Cars & Trucks

A replacement gas tank is the right fit when you want factory-style fuel storage for a restoration or street build. These tanks bolt into the original mounting points, so you keep the stock look without modifying the chassis. They're a direct path back to correct fitment.

OER replacement tanks come in zinc-coated, Ni-Terne-coated, and stainless steel versions. Applications include Camaro, Firebird, Impala, and Caprice models, with 16-24 gallon capacities depending on the vehicle. Pick the finish that matches your restoration goals and the original tank on your car.

For GM pickups, Auto Metal Direct offers a 16-gallon tank for short-bed trucks. A new tank often needs new hardware, so check the condition of your straps, filler neck, and sender before reassembly. You'll find those parts in fuel tank components, including senders, filler necks, straps, and replacement tanks.

Fuel Sending Units, Fittings & Plumbing

Your fuel sending unit has to match your gauge's ohm range, or the gauge won't read correctly. The JEGS floatless sending unit uses a 0-90 ohm range. The Tanks Inc. GM-style sender uses a 0-30 ohm range, so confirm your gauge spec before you order.

From the tank or cell, fuel travels through the pump, filter, and lines to the engine. Shop fuel pumps, regulators, and filters sized for your engine's fuel demand. Then connect everything with fuel line fittings, adapters, and hose that match the ports on your tank or cell.

If you're adding an electric pump, follow our guide to installing an electric fuel pump before you start. Older rubber lines can crack and leak over time. Check our guide on how often to replace rubber fuel lines before reusing old hose.