Regan Brown
Installing a second fuel tank can be a great way to increase your vehicle's range and explore new places without worrying about fuel. An auxiliary or replacement fuel tank can significantly increase your vehicle's capacity, doubling it in some cases. The process involves connecting the new tank to the vehicle's fuel system and may require skills with tools and mechanical knowledge. There are various options for adding a second fuel tank, such as using a transfer pump, gravity feed, or an electric fuel pump, each with its advantages and considerations.
Characteristics and Values of Installing a Second Fuel Tank
| Characteristics | Values |
|---|---|
| Benefits | Double the capacity of your fuel tank |
| No need for jerry cans, which can be messy, smelly, and frustrating | |
| More opportunities to explore remote areas | |
| Types of Tanks | Aux, add-in, or transfer tanks |
| Replacement tanks | |
| Installation | Can be installed by a trained professional or by the vehicle owner if they are skilled and have the right tools |
| Installation time can be just a few hours | |
| Fuel Transfer | Can use gravity or an electric pump to transfer fuel to the main tank |
| A lever valve can be added to the secondary fuel pipe to control fuel transfer | |
| A non-return valve can be added to the secondary fuel pipe to prevent fuel from flowing back to the secondary tank | |
| Fuel Feeding | Tee into the return pipe may cause return fuel to run back to the secondary tank |
| Best to fit another fuel feed into the tank or filler pipe | |
| A purpose-built electric fuel pump can be used to enable the secondary tank to be lower | |
| If there is no fuel level gauge, an overflow pipe can be used to fill the secondary tank and prevent overfilling |
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What You'll Learn
Installing an auxiliary fuel tank
First, you need to purchase the right auxiliary tank for your vehicle. Tanks come in various shapes and sizes, and you should check the range statistics before buying one. Make sure to buy a tank that is compatible with your vehicle's model and fuel system.
Next, you will need to decide where to place the auxiliary tank. Some tanks can be installed as midship direct replacements, spare tire carrier aux systems, or after-axle or in-bed transfer tanks. Consider the accessibility and safety of the tank when choosing its location.
Now, you can start the installation process. If your vehicle has a fuel pump accessible from under the rear seat, you can fill the auxiliary tank directly through the window and drain it by gravity into the main tank. Alternatively, you can use a transfer pump, or even gravity, to transfer fuel from the auxiliary tank to the main tank. Ensure that you have a fuel level gauge for the main tank to prevent overfilling, and consider installing an overflow pipe to allow fuel to flow back to the secondary tank.
To feed fuel from the auxiliary tank to the engine, you can either tee into the return pipe or install a separate fuel feed. However, keep in mind that teeing into the return pipe may result in fuel running back to the secondary tank due to resistance. Installing a separate fuel feed or a purpose-built electric fuel pump can help mitigate this issue.
Finally, consider adding valves to control the fuel flow. You can add a lever valve to the secondary fuel pipe after the secondary tank to control the flow of fuel. Additionally, installing a non-return valve before the connection with the return pipe can prevent fuel from flowing back into the secondary tank.
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Connecting a second fuel tank
Installing a second fuel tank can be a complex process, and it is important to consider safety at all times. If you are unsure about any aspect of the procedure, it is recommended to consult a trained professional.
The first step is to decide on the location of the second fuel tank. It should be placed securely, with consideration given to any necessary fuel transfer mechanisms. One option is to place the second tank in the back of the vehicle, allowing for gravity to assist in transferring fuel to the main tank.
Next, you will need to decide on the method of fuel transfer. One common approach is to utilise a transfer pump, which can be manually or electrically operated. Alternatively, gravity can be employed by placing the second tank higher than the main tank, allowing for fuel to drain downwards.
When connecting the second fuel tank, it is crucial to consider the fuel lines and potential issues with fuel return. One suggestion is to tee into the return pipe; however, this may result in return fuel flowing back to the secondary tank. To address this, you can install a non-return valve on the secondary fuel pipe, preventing fuel from flowing back into the secondary tank.
Additionally, consider including an overflow pipe from the main tank to the secondary tank. This serves as a safety mechanism to prevent overfilling the main tank, and it can also be utilised to fill the secondary tank.
Finally, ensure that all connections are secure and that there are no leaks. Consult a professional mechanic if you have any doubts or concerns about the installation.
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Using a transfer pump
There are a few things to consider when using a transfer pump. Firstly, it is important to ensure that the transfer pump is compatible with your vehicle's electrical system. In most cases, a 12V transfer pump will be suitable. It is also important to consider the location of the transfer pump. In some vehicles, the transfer pump is located on the driver's side frame rail, between the rear axle and the rear tank.
Another consideration is the type of transfer pump to use. There are two main types of transfer pumps: electric and mechanical. Electric transfer pumps are powered by the vehicle's electrical system, while mechanical transfer pumps are typically driven by the engine. Electric transfer pumps are generally more convenient and easier to install, but mechanical transfer pumps may be more reliable in some cases.
Additionally, some transfer pumps may require a fuel gauge to monitor the fuel level in the auxiliary tank and activate the transfer pump when needed. It is also important to consider the safety implications of using a transfer pump. In the event of a leak, an electric transfer pump can be shut off immediately, while a gravity setup may result in fuel leaking onto the ground without the driver's knowledge.
Finally, it is important to consider the cost of the transfer pump. Transfer pumps can range in price from around $39 to $150 or more, depending on the type and quality of the pump. It is important to choose a pump that is suitable for your vehicle and your specific needs.
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Filling the secondary tank
Another approach is to install a dedicated fuel feed for the secondary tank. This can be done by adding another fuel feed to either the tank itself or the filler pipe. This method ensures that the secondary tank can be filled directly and independently from the main tank.
If you opt for a gravity feed system for the secondary tank, you can consider a setup where the fuel is added through a window and then drained by gravity into the main tank. This design keeps the mass between the axles and provides easy access for refuelling.
Additionally, for those seeking a more straightforward solution, purchasing a purpose-built electric fuel pump can be an option. This pump enables the secondary tank to be positioned lower in the vehicle, providing convenience and flexibility in the overall setup.
It is important to note that the filling process for the secondary tank should always be carefully planned and executed to prevent any issues with fuel overflow or complications with the fuel return lines.
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Feeding from the second tank
When feeding from the second tank, you should consider how to prevent the return fuel from running back into the secondary tank. One option is to fit another fuel feed into the tank or filler pipe. This could be done by purchasing a small, purpose-built electric fuel pump, which will enable the secondary tank to be lower in the vehicle. If your vehicle does not have a fuel level gauge for the main tank, consider installing an overflow pipe from the main tank back to the secondary tank to prevent overfilling. This overflow pipe could also be used to fill the secondary tank.
Another option is to add a lever valve to the secondary fuel pipe after the secondary tank, using gravity or an electric pump to transfer fuel to the main tank. A non-return valve can also be added to the secondary fuel pipe to prevent fuel from flowing back into the secondary tank. Consider whether transferring fuel can be done safely with the engine on or off.
If you are able to use gravity feed, you may be able to fill the secondary tank through a window and drain it into the main tank, keeping the mass between the axles. You can then reach back and open a valve to transfer the fuel.
These options will help you effectively feed from the second tank and prevent issues with return fuel running into the secondary tank.
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Frequently asked questions
Installing a second fuel tank can be a complicated process. It is recommended that you consult a trained professional to do this. However, if you know your way around vehicles, are skilled with wrenches, and have the appropriate tools, you may be able to install one yourself.
Installing an auxiliary or replacement fuel tank can nearly double your vehicle's capacity, giving you more opportunities to explore.
The process involves connecting the new tank to the vehicle's fuel system and ensuring that fuel can be transferred between the two tanks. This can be done through gravity or with an electric pump.
You may want to consider the placement of the new tank and any necessary modifications to your vehicle, such as welding a cage to hold the tank in place and ensuring the safety of the installation.
