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MOUNTING "CAGE" FOR FUEL AND OIL TANKS
A mounting structure was built with 1" square tubing to hold the fuel cell can and dry sump tank. On top of this are the "firewall" panels that seal the passenger compartment from these hot/flammable fluids as well as the underside of the car.
The structure started out as a perimeter section of tubing and eventually lower sections were added for the fuel cell can. Then the bolt-on upper section for the can, too.
After that the bracket to hold the ARE billet oil tank mount was formed from steel sheet, with some dimple die holes to add stiffness and remove weight.
ENCLOSURE TO COVER OIL TANK AND FUEL CELL
Now that the tank/cell mounting cage was bolted into the car the openings through the trunk floor needed to be sealed. There also needed to be metal coverings for the dry sump tank and fuel cell as well, to keep fluids and fire away from the cabin.
First the enclosure for the top of the fuel cell was built from more aluminum sheet.
These were cut using cardboard templates, then taped together and trimmed, tack welded and final TIG welded. This "can" mounts inside the 1" steel tubing structure.
But wait, there's more! A giant 3-piece enclosure was needed for the oil tank side. The enclosure was too tall and unwieldy to be made from 1 piece, so it's 3 pieces.
We need to make an easy to access hatch to check the oil tank levels (dipstick) and there's still a flat panel that needs to go between the two upper enclosures but for the most part it is done. They aren't exactly "pretty" to look at but they are very functional and necessary. We might add a shrubbery or something to distract the D&E judges...
LEXAN SIDE AND REAR WINDOWS + FUEL FILL
To lower weight we added Lexan rear quarter windows and back windows. Then we added a fuel filler neck in one of these windows, and an enclosure around the filler neck.
We sourced the rear quarter and back windows from Five Star, a race car supplier. These were mocked up on the car above to check for fit, which was very good.
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