Accomplishments
(as of 12/20/07)
Click on the pictures below to open full-sized images in a new windowThe Tank
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Since it takes more E85 than gasoline to travel a certain distance, the snowmobile needs a new tank in order to finish the 100 mile endurance race. We chose to construct the new tank out of composites, because it will be lightweight, strong, and aesthetically pleasing. The first step was to order a second tank and make a plug that has the dimensions of the desired new tank. This was done by adding foam to the spare tank and then covering the whole thing in automotive body filler. After a lot of sanding, the plug had the correct shape. This completed plug will later be used to create a mold, which will allow a real fiberglass and carbon-fiber tank to be made. Recently we painted the plug with a high gloss paint, and waxed a section of it to test the plug with composite removal. We created a coupon of fiberglass, layed it on the plug, and then removed it once it cured. This shows that we should be able to remove the fiberglass mold from the plug when the time comes. |    |
The Fuel System
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The Phazer's stock fuel system wasn't rated for ethanol, so we replaced critical components with E85 high-capacity equipment. The pump and the fuel pressure regulator are from Edelbrock, and the fuel filter from Jegs. Everything is connected with Goodyear E85 capable EFI hose. We also soaked a non-critical surface of the stock fuel rail in ethanol and checked it for signs of softening. Since it was still as hard after its soak as before, we will be able to use it as part of the fuel system. So far we have completed a bench test of the entire fuels system, including quick disconnects, and have provided the rail with 60 psi pressure. |   |
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We had to elimanate the stock fuel pressure regulator because it wasn't compatible with ethanol. This old regulator was mounted at the end of the fuel rail. Since our new regulator sits in the line before the rail, we needed to cap the end of the rail to make a closed fuel circuit. The cap we made is composed of stainless steel, which is impervous to ethanol. It was designed to fit into the rail just as the stock gasket between the rail and fuel regulator did, only without the hole in the center (the hole allowed fuel to flow from the rail into the old regulator and then through the return line to the tank). We used the stock O-ring from the old gasket to create the seal, after making sure the O-ring was compatable with ethanol by soaking it over a few days. Thanks goes to Matt Fowler at the AMC for performing the precision lathe work on this part. |   |
New Battery
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| We noticed that the Phazer is a rather hard sled to start up, even when it's warm. So, anticipating the cold-start test at the competition, we purchased a bigger battery with a higher capacity and more cold cranking amps. The above photo shows the battery with the sealed battery box we obtained. We plan on mounting the battery box at the rear of the sled below the brake light. |