Katerina Swanson
Auxiliary fuel tanks are a great way to extend your driving range, but there are some important considerations to keep in mind, especially when dealing with gasoline. While auxiliary tanks for diesel trucks are widely available and compatible with most models, gasoline auxiliary tanks are subject to stricter regulations due to safety concerns. The law prohibits gasoline tanks from withdrawing fuel through connections below the fuel level, which means that in-bed auxiliary tanks with top connections are generally permitted. However, gravity feed systems that transfer gasoline from an auxiliary tank to the main tank are not allowed. Additionally, there may be limitations on the number of gallons you can carry and the placement of the auxiliary tank. Installing an auxiliary fuel tank can be a complex process, and it is recommended to consult with specialized auto fabrication shops to ensure proper installation and compliance with legal requirements.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Possibility of installing an auxiliary fuel tank | Yes, possible to install in older trucks, but may be challenging for newer trucks |
| Safety concerns | Volatile and combustible material; concerns about DIY installation and ensuring proper fitting, exhaust and heat management, crash vulnerability, and plumbing |
| Legal considerations | External refueling systems with auto-shutoff nozzles are DOT-legal; in-bed auxiliary tanks with top connections can pump/siphon to the main tank; gravity feed tubes from auxiliary to main tank are not allowed for gasoline |
| Tank capacity | Varies, e.g., 37 gallons, 40 gallons, 50 gallons, 60 gallons, 100 gallons, 110 gallons, 150 gallons |
| Installation considerations | Vent lines, pump lines, siphon preventer valves, fuel transfer pumps, compatibility with truck model and fuel type (diesel vs. gasoline) |
| Benefits | Extended driving range, reduced frequency of refueling, cost savings due to buying fuel in cheaper locations |
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What You'll Learn
Installing an auxiliary fuel tank in a truck bed
Firstly, ensure you have a high enough rated jack to safely lift your truck. Once your truck is lifted, make sure you do not go under the vehicle while it is only supported by the jack. Use appropriately sized jack stands placed on flat portions of the truck frame for added safety.
Next, you will need to prepare the truck bed by removing any items, such as a bed mat, to create a spacious and safe working environment. Mark the placement of the auxiliary fuel tank, ensuring it is away from the sides, front, and back of the bed to prevent the tank from rubbing against the truck bed and causing potential damage.
After marking the mounting locations, remove the auxiliary fuel tank from the bed and use a centre punch to mark the exact locations of the holes. Drill pilot holes, then drill the final holes with a bit that matches the size of your bolts. Before drilling, check the undercarriage to avoid drilling into your existing fuel tank or other important components.
Now, you can bolt your new tank into place. Determine how you will run the fuel supply line from the new tank to the existing factory tank. Most owners drill another hole in the truck bed and thread the line down to the factory tank filler neck. Alternatively, you can access the bottom side of the truck bed by removing rubber plugs near the bottom of the stake pocket support posts, cutting a hole in the centre of the rubber plug, and inserting the rubber fuel line.
Finally, place your auxiliary fuel tank in position and fasten it securely using bolts, nuts, and washers. Having an extra set of hands can be helpful during this step to hold the nuts and bolts in place as you tighten them.
By following these steps, you can successfully install an auxiliary fuel tank in your truck bed, increasing your fuel capacity and extending your driving range.
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Legal requirements for auxiliary fuel tanks
The legality of auxiliary fuel tanks depends on several factors, including the type of fuel, the vehicle's specifications, and the state and federal regulations in the region. Here are the key legal requirements for auxiliary fuel tanks:
- Compliance with Regulations: Auxiliary fuel tanks must comply with various state and federal regulations. These regulations are enforced by agencies such as the Environmental Protection Agency (EPA), Federal Motor Vehicle Safety Standards (FMVSS), Vehicle Equipment Safety Commission, National Fire Prevention Association, and the Recreational Vehicle Industry Association.
- Manufacturing Standards: Liquid fuel tanks manufactured on or after January 1, 1973, must conform to specific standards. For example, gasoline tanks mounted on buses must adhere to certain rules, as outlined in the Federal Motor Vehicle Safety Standards.
- Gravity Feed Fuel Systems: Gravity feed fuel systems are a controversial topic. Some sources claim that they are illegal due to safety and environmental concerns, while others suggest they may violate portions of US DOT regulation 49 CFR 393.67. Gravity feeding or siphoning is prohibited according to 49 CFR CH.III (393.65) 6d.
- Fuel Type and Vehicle Weight: The legal requirements can vary depending on the fuel type and the vehicle's gross vehicle weight rating (GVWR). For example, gasoline- and methanol-fueled vehicles with a GVWR of 3,744 kg (8,500 pounds) or less must adhere to specific fill rate requirements set by the EPA.
- Filling and Venting: Each fill pipe must be securely capped to prevent fuel spillage. Additionally, liquid fuel tanks with a capacity of more than 25 gallons must have a safety venting system to prevent tank rupture in the event of a fire.
- Fuel System Integrity: Motor vehicles that meet the fuel system integrity requirements of 49 CFR 571.301 are exempt from specific subpart requirements. Transfer Flow, Inc. emphasizes the value of NHTSA's Fuel System Integrity testing, utilizing FMVSS 301 standards to ensure the safety and legality of their fuel systems.
- State-Specific Regulations: Certain states have their own specific regulations for auxiliary fuel tanks. For example, California has the California Code of Regulations (CCR) and the California Air Resources Board (CARB), which regulate fuel systems.
It is important to note that the information provided here may not be exhaustive, and it is always advisable to consult the specific laws and regulations in your state or region to ensure compliance with the legal requirements for auxiliary fuel tanks.
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DIY installation vs custom fabrication
Installing an auxiliary fuel tank in your vehicle can be a great way to extend your driving range and provide peace of mind during emergency situations. However, there are two main approaches to consider: DIY installation or custom fabrication. Here is a detailed comparison between the two options:
DIY Installation
DIY installation of an auxiliary fuel tank can be a challenging but rewarding task. While it may be more cost-effective than custom fabrication, it requires careful planning and execution to ensure safety and functionality. Here are some key considerations for DIY installation:
- Design and Measurement: Before starting, take precise measurements of the space where you plan to place the fuel tank. Consider the space required for fuel pickups, vents, fuel filler, mounting straps, fuel level sensors, and fuel lines. Draw your design on paper, ensuring that your fuel tank will fit perfectly and allow for easy access to all necessary components.
- Material Selection: Choose a suitable material for your fuel tank, such as aluminum or steel. Aluminum is lightweight, resistant to corrosion, and a popular choice for fuel tanks. However, it is challenging to weld, so you may need to consult a professional welder for this step.
- Prototype and Testing: Build a prototype of your fuel tank using cardboard or similar materials to ensure a perfect fit. Once you're satisfied with the design and placement, pressure test your fuel tank to check for leaks. This step is crucial, as even small pinholes can cause fuel leaks.
- Installation: When installing the fuel tank, ensure it is securely mounted and doesn't rub or come into adverse contact with any part of the vehicle. Follow safety guidelines and consider the proximity of the exhaust and heat management.
Custom Fabrication
Custom fabrication involves hiring a specialized company or auto fabrication shop to design and install the auxiliary fuel tank for you. While this option can be more expensive, it offers several advantages:
- Expertise and Safety: Custom fabrication shops have the necessary expertise and equipment to ensure a safe and proper installation. They will consider factors like exhaust routing, heat management, crash vulnerability, and plumbing to ensure your fuel tank meets industry standards.
- Time Savings: Custom fabrication can save you significant time and effort compared to DIY installation. The professionals will handle all aspects of the design, fabrication, and installation, allowing you to focus on other priorities.
- Customization: Custom fabrication shops can create a fuel tank that perfectly matches your vehicle's specifications and your personal preferences. They can also advise you on the best materials, sizes, and configurations for your needs.
- Peace of Mind: With custom fabrication, you can rest assured that your auxiliary fuel tank has been installed correctly and safely. This peace of mind is invaluable, especially when dealing with volatile and combustible materials like gasoline.
In conclusion, both DIY installation and custom fabrication have their advantages and disadvantages. DIY installation can be more affordable but requires significant time, effort, and knowledge. On the other hand, custom fabrication offers expertise, safety, and customization but comes at a higher cost. Ultimately, the decision depends on your budget, skill level, and the level of customization you desire.
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Transfer pumps vs gravity feed
Auxiliary fuel tanks are designed to supplement the existing fuel tank of a vehicle. They are typically installed in the bed of a truck and are used when extended range or prolonged operation without refuelling is required. They have their own fuel transfer system, which can be an inline fuel pump or a gravity feed system.
Gravity feed fuel systems are a simpler method of transferring fuel, as they do not require a pump. However, gravity feed systems can only be used with diesel fuel and not gasoline. This is due to safety, environmental, and legal concerns, which are inherent in the design and performance of gravity-fed auxiliary fuel systems. In addition, gravity feed systems can adversely affect federally mandated, manufacturer-implemented, on-board vehicle diagnostic systems. For example, gravity feed systems can keep the main fuel tank overfull, resulting in a diagnostic trouble code.
Transfer pumps, on the other hand, can be used with gasoline and diesel fuel. They are equipped with hoses and dispensing nozzles to facilitate the transfer of fuel to other equipment, vehicles, or storage tanks. Transfer pumps are more versatile than gravity feed systems, as they can be used to refuel multiple vehicles and equipment. They are commonly used in industries such as construction, agriculture, and fuel delivery services.
One disadvantage of transfer pumps is that they require a power source to operate, which can be a problem if access to power is limited. Transfer pumps also have a higher upfront cost compared to gravity feed systems.
In terms of space and weight considerations, gravity feed tanks tend to be lower profile and take up less space, while transfer tanks with pumps and hoses may require more room.
Both transfer pumps and gravity feed systems have their advantages and disadvantages. Transfer pumps are more versatile and suitable for gasoline, but they come with a higher upfront cost and require a power source. Gravity feed systems are simpler and do not require a pump, but they can only be used with diesel fuel and may affect vehicle diagnostic systems. Ultimately, the decision between a transfer pump and a gravity feed system depends on the specific needs and requirements of the user.
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Fuel tank capacity and range
Auxiliary fuel tanks, also known as transfer tanks, are additional tanks installed in vehicles to extend their fuel capacity and, consequently, their driving range. These tanks can be particularly useful for those who frequently tow heavy loads or travel in remote areas, reducing the need to stop for refuelling.
When it comes to fuel tank capacity, there are various options available for auxiliary fuel tanks. These tanks come in different sizes, typically ranging from 37 to 100 gallons, with some even considering tanks in the 150-gallon range. The choice of tank size depends on the vehicle's fuel efficiency, the distance travelled between refuelling stops, and the desired increase in range.
It is important to note that the legality of auxiliary fuel tanks for gasoline varies. While some jurisdictions allow their use, there are often specific regulations that must be followed for safety reasons. For example, in the United States, the Department of Transportation (DOT) has specific requirements for auxiliary fuel tank systems, particularly regarding the withdrawal of fuel and the prevention of siphoning. As such, it is essential to consult local laws and regulations before installing an auxiliary fuel tank.
Additionally, the installation process for auxiliary fuel tanks can be complex, especially for gasoline tanks due to the volatile nature of the fuel. It is recommended to consult professionals or specialised shops for proper installation, ensuring that all plumbing, exhaust, heat management, and crash vulnerability concerns are addressed.
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Frequently asked questions
Yes, it is possible to install an auxiliary fuel tank in your truck. Auxiliary fuel tanks were common in older trucks, but you may need to take your vehicle to a custom auto fabrication shop to ensure it is installed properly.
While it may be possible to install an auxiliary fuel tank yourself, it is not recommended due to safety concerns. Fuel tanks contain volatile combustible material, and there are also exhaust and heat management issues to consider, as well as crash vulnerability.
Yes, it is possible to put an auxiliary fuel tank in the bed of your truck. However, there are legal considerations to take into account, especially when dealing with gasoline.
According to US law, a gasoline tank cannot withdraw fuel from a connection below the fuel level. This means that an in-bed auxiliary tank with top connections can pump or siphon to a vehicle's main tank without issue. However, it is illegal for an auxiliary gasoline tank to gravity feed into another gas tank.
Transfer Flow, Inc. is a reputable manufacturer of auxiliary fuel tank systems, and their website has resources about safe and legal systems.
