Katerina Swanson
Installing a second fuel tank is a complex process that requires careful consideration and planning. It involves purchasing the necessary parts, such as a fuel selector valve, connector harness, and toggle switch, as well as ensuring that the second tank is properly connected and integrated into the vehicle's fuel system. Some people opt for a gravity feed system, while others prefer to use a transfer pump to move fuel between the tanks. In addition, it is important to consider the placement of the second tank and any potential impact on the vehicle's centre of gravity, especially in boats. Custom tanks can be made to fit specific dimensions, and proper ventilation and mounting are crucial to ensure safety. Overall, adding a second fuel tank can provide increased fuel capacity and flexibility, but it requires a good understanding of the vehicle's fuel system and careful installation to avoid potential issues.
| Characteristics | Values |
|---|---|
| Fuel tank type | Gas, diesel, or auxiliary |
| Vehicle type | Car, truck, or boat |
| Tank material | Aluminum, plastic, or nylon |
| Tank capacity | Varies, e.g., 40-gallon, 50-gallon, 55-gallon |
| Filler type | Fuel filler pipe with a "tee" or "Y" connector |
| Ventilation | Vent hose or vent line |
| Fuel gauge | OEM gauge, inline fuel pump, or SPDT switch |
| Switching mechanism | Fuel selector valve, diverter valve, or dual-circuit ball valve |
| Pump mechanism | Inline pump, transfer pump, or gravity feed |
| Legal considerations | Check for fire hazards and leaks |
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What You'll Learn
Parts needed for installation
The parts needed for installing a second fuel tank vary depending on the type of vehicle and the specific setup you are aiming for. Here are the common parts and considerations for installation:
Fuel Tanks
Firstly, you will need to source the additional fuel tank or tanks. For vehicles like trucks, you may opt for an auxiliary tank, while for boats, you might consider a bladder-type tank or an aluminium/custom-made tank. Ensure the tank fits within the available space and complies with safety regulations.
Fuel Transfer System
You will need a mechanism to transfer fuel between the tanks and to the engine. This can be achieved through various methods:
- Gravity Feed System: This setup uses gravity to feed fuel from the second tank to the primary tank. It requires hoses connecting the top and bottom of both tanks for air and fuel movement. No additional pump is needed, but you must consider the legalities and potential leak hazards of this system.
- Fuel Pump: An electric or inline fuel pump can be installed to transfer fuel between the tanks. This method provides more control over fuel transfer but may require additional plumbing and wiring.
- Transfer Pump and Momentary Switch: This setup uses a transfer pump and a switch to manually control fuel transfer between tanks.
Valves and Connectors
To manage the fuel flow between tanks and to the engine, you will need valves and connectors:
- Y-Fitting or Y-Connector: This connector joins the supply, return, and vent lines of both tanks, allowing fuel to flow between them and maintaining equilibrium.
- Manual Mechanical Diverter Valve: A diverter valve allows you to manually switch between tanks while driving. It can be mounted under the driver's seat, providing a simple and cost-effective solution.
- Dual Circuit Ball Valve: This valve switches the supply and return lines simultaneously, ensuring proper fuel flow between the tanks.
Fuel Gauge and Wiring
To monitor fuel levels in the second tank, you may need additional wiring and a fuel gauge:
- Fuel Gauge: A fuel gauge specific to the second tank will allow you to accurately monitor its fuel level.
- Wiring: Wiring is necessary to connect the fuel gauge to the sending unit of the second tank. This wiring will enable the gauge to display the fuel level accurately.
It is important to consult with professionals or experts in the field to ensure that all parts are compatible and safely installed, and to check for any specific requirements or regulations that may apply to your vehicle or location.
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How to switch between tanks
There are several methods for switching between two fuel tanks. One method is to use a manual dual-port valve to switch between the two tanks. This involves mounting the valve under the cab with the lever coming through a rubber grommet in the cab floor. The valve will have multiple ports, allowing you to select different tanks or an "off" position.
Another method is to use a gravity feed system. This involves mounting a second tank and connecting the two tanks with hoses. The hose at the bottom allows fuel to flow in and out, while the hose at the top allows air to move in and out. This system does not require a secondary pump or transfer pump.
A third option is to use a transfer pump and momentary switch to move fuel between the tanks. This method allows you to keep the tanks separate and avoid potential leaks.
Additionally, you can plumb the two tanks together to create a single large fuel supply. This involves joining the supply lines, return lines, and vent lines of both tanks with Y-connectors. This will maintain equilibrium between the tanks, keeping the fuel level the same on both sides.
Finally, you can add a tube between the two tanks at their lowest level to maintain equal fuel levels in both tanks. This method prevents fuel imbalance, but the tube may become a snag point when traversing rough terrain.
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Pros and cons of gravity feed
Adding a second fuel tank to your vehicle can be a great way to increase your range and fuel capacity. One option for managing the transfer of fuel between the two tanks is to use a gravity feed system. This involves positioning the auxiliary tank higher than the main tank and allowing the fuel to flow downwards through a valve or hose. Here are some pros and cons of using a gravity feed system for your second fuel tank:
Pros:
- Simplicity and Cost-Effectiveness: Gravity feed systems can be simpler and more cost-effective than installing an additional fuel pump. They require fewer components and can be easier to install and maintain.
- Fuel Transfer Without a Pump: By utilising gravity, the fuel can be transferred from the auxiliary tank to the main tank without the need for a mechanical pump. This eliminates the cost and complexity of installing an additional pump.
- Reduced Risk of Fuel Backup: With a gravity feed system, there is a reduced risk of fuel backing up into the charcoal canister, which can cause issues with drivability and engine performance.
Cons:
- Limited Gravity Feed: One challenge with gravity feed systems is that the fuel flow relies solely on gravity. As a result, you may not achieve a significant gravity feed effect unless you also install a vent line from the main tank to the auxiliary tank. Without adequate ventilation, a vacuum can build up and impede the fuel flow.
- Potential for Fuel Overflow: If not properly controlled, there is a risk of fuel overflowing from the auxiliary tank into the main tank. This can occur if the valves or switches between the tanks are not properly configured or if there is no mechanism to stop the fuel transfer once the main tank is full.
- Refueling While Driving: Some users recommend refuelling while the vehicle is stopped due to the environmental equipment on most gas-powered vehicles. Refuelling while driving may increase the risk of fuel spills or environmental hazards.
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Using a bladder or portable tank
A bladder or portable tank is a great way to extend your boat's range and provide increased security and peace of mind, especially on long-range trips where fuel availability may be limited. Bladders are collapsible and made from flexible, rubber-coated fabric. They are lightweight, portable, and highly durable, making them easy to transport and set up. They are also available in a variety of shapes and sizes, ranging from 25 gallons to 500 gallons.
When considering a bladder or portable tank, it is important to keep in mind the available storage space and anticipated fuel requirements. For example, if you have limited space, you may opt for a smaller bladder that can be stored in a more compact form when not in use. Additionally, you should ensure that the bladder is properly secured and supported, especially in marine and aviation settings, as local, state, and federal regulations may require secondary containment.
When using a bladder or portable tank, you will need to transfer the fuel to the main tank or motor. This can be done using a portable transfer pump, or in some cases, by siphoning or gravity-feeding the fuel if the bladder is located higher than the fuel tank. It is also important to consider the ventilation and weight distribution of your boat when adding a second fuel tank. Avoid placing the bladder under the deck due to the danger of abrasion or fumes accumulation. Keep flammable liquids topside and away from the engine, and always follow safety regulations.
Some users have expressed a preference for installing a second hard tank instead of a bladder due to concerns about leaks and durability. However, others have found bladders to be a convenient and satisfactory solution for their fuel storage needs, especially when custom-made to their specifications. Ultimately, the decision between a bladder or portable tank and a hard tank depends on individual preferences, the boat's specifications, and the intended use.
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$472.53
Plumbing two tanks together
Plumbing two fuel tanks together involves connecting the tanks using hoses and valves to allow fuel transfer between them. Here is a step-by-step guide on how to achieve this:
Firstly, mount the second fuel tank securely in a suitable location, ensuring it is stable and safe. This may involve purchasing a custom tank that fits the available space. It is important to consider the ventilation and mounting of the tank to avoid issues with fumes and abrasion.
Next, connect the two tanks using hoses or pipes. One hose should be connected at the bottom of the tanks to allow fuel to flow in and out, while another hose at the top ensures air movement and ventilation. These hoses should be securely attached to prevent leaks.
You can then choose to connect the tanks with a Y-fitting or a Y-connector, which allows the supply lines, return lines, and vent lines to be joined together. This setup will enable equilibrium between the tanks, maintaining the same fuel level in both.
Additionally, consider installing a fuel selector valve, connector harness, and a toggle switch. This setup will allow you to switch between tanks easily. You can wire the sending unit to the dashboard gauge, so you can monitor the fuel level in each tank accurately.
Finally, ensure that you comply with any legal requirements and safety standards for your specific vehicle and location. It is important to consult professionals or experts if you are unsure about any part of the process.
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Frequently asked questions
You will need a fuel selector valve, a connector harness, and a toggle switch. You can buy these parts from a store like CarQuest.
You can connect the two tanks with a Y fitting and eliminate a second pump. Use a manual mechanical diverter valve to switch between tanks. You can also use a gravity feed system, but you will need to check the legalities of this setup.
When refueling, you will need to add fuel to both tanks. The tanks will not equalize if you only fill one of them. You will also need to consider the ventilation and mounting of the second tank, especially if it is installed in a boat.
