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91 XR2 Modification and 93 XR2 all original

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9193CapriXR2:
This is not necessarily a build thread but more of a motivational tracker to keep me going through the winter months.  I have a 1993 XR2 with 41,000 original miles that other than a few maintenance items like fuel filter and belts it's all original.  It's the car to the left in the picture.  Then I have a 1991 XR2 that I'm going to modify the crap out of.  It's fluid and nothing set in stone at this time bit first and foremost is mechanical.  I've already replaced all the filters, shifter bushings, both CV axles, water pump, timing belt, radiator, cooling fan switch, valve cover and timing cover gaskets, plugs, wires, cap and rotor, battery, center console, door speakers, and head unit. 

Next on agenda is complete brake overhaul to include all calipers (still need to find a right rear) brake hoses, rotors, pads, bearings, seals, and fluid flush. 

Then all four struts with the 2" lowering springs.

Then I'll be ripping out the stock fuel tank, straps, and filler neck and replacing it with a 8 gallon fuel cell mounted in the trunk.  Once this is completed I'll be shaving the fuel door.

Then door poppers and shaving handles and key locks on doors. 

Then I'm either going to have hood, headlight doors, hardtop, trunk lid, and spoiler wrapped in carbon fiber or plasti-dipped in Black. 

Plan on running a stainless exhaust pipe with a small muffler from manifold and have it dump behind passenger front tire.

Removing back seat for weight savings

And many other things clanging around in my skull

https://photos.app.goo.gl/vEQnyVkfSQTi1wZF7

https://photos.app.goo.gl/azdCfZWofAWrLEAC7

EShepherd:
Damn man, the one on the left managed to stay CLEAN. Looking forward to the progress.

9193CapriXR2:
Thanks.  It's never seen a winter.  I'm actually hoping the 91 turns out nicer when all said and done.

9193CapriXR2:
First question...what rating should fuel pump be to adequately pump fuel from fuel cell to engine?  What I've found online is that the stock pump is rated at 60 gallons per hour.  I am assuming I'll need at least that.  Is there any harm going higher?  Will the pressure regulator taper it down to what is needed by the engine?  I found some 100 GPH pumps at a very reasonable price.

Thanks ahead of time.

Rocketman:
Yes, too high a LPH rating will heat the fuel since it's pumping way more than needed and bypassing most of it

I would not recommend a fuel cell in the trunk, I have one in the GTXR2 as I had no other option at the time. I believe it's a 15 gallon
Pros: -Works with the AWD system (driveshaft interference with OEM tank, could not source a OEM awd tank /pumps/ pump controller at the time)

Cons: -Had to add aftermarket fuel gauge to work with the fuel cell sender, Fuel gauge is a bit wonky, does not seem linear
-Popping trunk to fuel up is inconvenient
-Fuel slosh is problematic, with ~3/4 gallons remaining the sump can run dry during cornering
-Weight of fuel moved all the way to the rear and higher up
-Extra expense of external fuel pump, braided lines, bulkhead fittings, evap line/rollover concerns
-My install would likely not pass a modern state safety inspection, would not pass scrutiny of a racetrack either. Do not care for the hazard of having fuel in the rear crumple zone. If I ever get the GTXR2 going again I will be fabricating a custom tank as close to OEM location so I can use the fuel door again, it was my biggest pet peeve with that whole project

Just my $0.02 on experiences with the fuel cell

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