Lotus 2ZZGE Baffled Fuel Tank - New Design

We've started work on a new baffled fuel tank that is built from an OEM tank.  Over the years, we have offered a couple of different designs with pros and cons.  Our V2tank was built for us by Ralph@V2 and featured ATL trap doors that did a good job but were noisy.  When Ralph retired, we had to develop a new solution.  

This second product the 111tank, was modelled after the factory baffled tank that was no longer available.  This tank had no moving parts and proved to be a good solution - for most.  We had two clients who suffered fuel starvation, one with a Honda conversion and another with the 2ZZGE.  This made us relook at our design.

ProAlloy have been making baffled tanks for many years but they were patterned after the Euro tanks and were not a direct replacement for the North American tanks.  To maintain our emissions and safety plumbing, utlizing a factory tank was more ideal.  ProAlloy use a ball check valve in their design.  This simple design has been very effective and one that we've decided to follow.

This image shows our baffle design with the check valves.  We are using a stainless baffle and will attach the valves to it.  We will open up the end of the tank, remove the old baffle and then replace it with our design.  One challenge that exists with this design is that the float that registers fuel level could potentially interfere with the valve.  We will need to test this out and possibly move the location of one valve.

We are on track to getting the first prototype built and into our ArtCar2 by the beginning of 2026.