Regan Brown
Adding a second fuel tank to your vehicle or boat can increase its range, but there are several factors to consider, including legal requirements. The placement of the second tank is crucial, as it can affect the centre of gravity and handling. For boats, custom tanks can be made to fit specific dimensions, while for vehicles, tanks can be placed under the cab or bed, or even above the spare tire. Ventilation is another important factor, as fumes can accumulate in enclosed spaces. The use of valves, switches, and pumps can help manage fuel transfer between tanks and ensure a proper fuel supply. Some companies offer kits with the necessary parts and paperwork for a legal installation.
| Characteristics | Values |
|---|---|
| Ventilation | The second fuel tank needs to be vented. |
| Weight distribution | The weight of the second fuel tank might shift the center of gravity and affect the handling of the vehicle. |
| Customization | Custom tanks can be made to fit specific dimensions and spaces in the vehicle. |
| Fuel transfer | A fuel selector valve or a toggle switch can be used to transfer fuel between the main and secondary tanks. |
| Fuel management | A fuel management system can automatically transfer fuel from the auxiliary tank to the main tank to maintain equal fuel levels. |
| Fuel filler | The fuel filler hose needs to be considered when installing the second fuel tank. |
| Vent hose | The vent hose should be 3/4" OD or 5/8" ID to allow for proper ventilation. |
| Fuel line | A fuel line needs to be run from the second fuel tank to the motor or main tank. |
| Fuel pump | A fuel pump can be used to move fuel from the secondary tank to the main tank. |
| Fuel valve | A valve connector on the fuel line allows the use of one tank or the other. |
| Fuel gauge | A gauge on the second tank may require additional wiring. |
| Fuel tank material | The fuel tank can be made of aluminum or plastic. |
| Fuel tank placement | The second fuel tank can be placed under the bed, behind the wheel well, or in the sides of the boat. |
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What You'll Learn
For boats, consider custom tanks or saddle tanks
If you are looking to add a second fuel tank to your boat, there are a few options to consider. Firstly, you can look into custom tanks that are built to fit the specific dimensions and requirements of your boat. This option may require finding a company that specialises in custom tank fabrication and providing them with detailed measurements to ensure a proper fit. You will also need to consider the venting and filler hose setup for a custom tank, ensuring that it can be accessed and clamped securely. Additionally, you may want to include a gauge on the custom tank, which will require running additional wires.
Another option for boats is to install saddle tanks, which are designed to be fitted on the sides of the boat. These tanks require careful routing of the fuel fill line and vent line, with specific hose dimensions to ensure proper function. You will also need to run a fuel line back to your motor and tie it into the existing system using brass valves. When considering saddle tanks, it is important to determine the size of the tank and calculate its fuel capacity.
In terms of materials, aluminium tanks are a popular choice for boats as they can be securely fastened to the hull using 5200 plastic strips and nylon straps. However, it is important to ensure that the tank is positioned above the bottom of the boat to avoid any issues with abrasion or fumes accumulation. Additionally, you may need to address ventilation and mounting concerns, especially if the tank is installed under the deck.
When adding a second fuel tank to your boat, it is crucial to consider the weight distribution and centre of gravity. The addition of a second tank can affect the boat's handling, so careful planning and installation are necessary to ensure a safe and functional setup.
If you are looking for a more portable solution, you can also explore the option of using portables. However, this will require appropriate plumbing to transfer the fuel to the motor or main tank.
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For trucks, consider a tank under the cab or the bed
For trucks, consider installing a second fuel tank under the cab or the bed. This option is ideal if you don't want to use valuable space in your truck bed. One user on a forum suggested that the best place for a second tank on a crew cab is under the cab on the driver's side. The tank could measure 16" width x 30" length x 10" height, which would give you approximately 24 gallons of fuel.
You could also consider adding a pancake tank under the bed. This option might be more difficult, but it's worth investigating. Another option is to redirect your exhaust so you can put a similar tank on the passenger side. However, this would likely require the exhaust to exit through the hood.
If you're handy, you could even consider a custom-built tank. One user on a forum mentioned a tank they saw made of 1/4-inch aluminum diamond plate that filled the bottom of a longbed 1 ton. It was 4 inches deep and reinforced from the inside, so it could carry a load on top of it. It held 98 gallons of fuel.
When installing a second fuel tank, you'll need to consider the ventilation and mounting. You'll also need to purchase additional parts, such as a fuel selector valve, a connector harness, and a toggle switch. You can find these parts at most auto parts stores. Additionally, you'll need to ensure that your second tank is legal and follows all necessary regulations.
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Use a fuel selector valve, connector, and toggle switch
If you're looking to add a second fuel tank legally, one method is to use a fuel selector valve, connector, and toggle switch. This setup allows you to run two separate fuel tanks and draw fuel from only one tank at a time. Here's a step-by-step guide on how to achieve this:
Step 1: Understanding the Components
The fuel selector valve is a crucial component that enables you to switch between the two fuel tanks. It has three ports: two inlets and one outlet. This valve ensures that fuel flows from only one selected tank to the engine. You can use a common toggle or rocker switch to control the valve. Additionally, you'll need clamps, wires, connectors, and hoses to complete the installation.
Step 2: Sourcing the Right Parts
When sourcing parts, ensure they are compatible with your vehicle's fuel system. You can find fuel selector valve kits online, specifically designed for vehicles with one main and one auxiliary fuel tank. These kits typically include the valve, clamps, wires, connectors, and other necessary components. Make sure to check the voltage requirements and hose barb sizes to match your vehicle's specifications.
Step 3: Installation Process
The installation process involves running separate fuel lines from each tank to the fuel selector valve and then a single line from the valve to your engine. This setup allows you to control which tank is supplying fuel by using the toggle switch. Ensure that the fuel lines are securely connected and follow any specific instructions provided with the fuel selector valve kit.
Step 4: Considerations and Precautions
It's important to note that fuel selector valves are typically not suitable for marine applications or vehicles with fuel return lines. Always refer to the manufacturer's instructions and precautions to ensure safe and proper usage. Additionally, consider the placement of the tanks and fuel lines to avoid issues with ventilation, mounting, and weight distribution, especially in boats.
By following these steps and considerations, you can legally add a second fuel tank to your vehicle or boat using a fuel selector valve, connector, and toggle switch. Remember to consult professionals or experts if you have any doubts or concerns during the installation process.
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Pump fuel from the auxiliary tank to the main tank
Adding a second fuel tank to your vehicle can be a great way to extend the amount of fuel you can carry, especially on long journeys or in remote areas. When adding an auxiliary fuel tank, it is important to consider the legal implications and ensure that any modifications are done safely and within the guidelines provided by regulatory bodies and vehicle manufacturers.
One key consideration when adding a second fuel tank is the method by which fuel will be pumped from the auxiliary tank to the main tank. Here are some detailed instructions and options to consider for setting up this fuel transfer system:
- Fuel Transfer Systems: There are several auxiliary fuel systems available on the market that can automatically transfer fuel from the auxiliary tank to the main factory fuel tank. These systems, such as the Fuelbox Auto Fuel Controller and the Trax 4 system, are designed to work with specific types of diesel trucks and can be set up for automatic or manual fuel transfer. The Trax 4 system, for example, allows you to set predetermined fuel levels to initiate the transfer, and it includes an LCD screen to monitor fuel levels.
- Manual Transfer Pump: Some auxiliary fuel tanks may be equipped with a manual transfer pump that you can switch on and off to transfer fuel from the auxiliary tank to the primary tank. This option gives you more control over the fuel transfer process, but it requires you to monitor the fuel levels in both tanks to ensure you don't run out of fuel in either tank.
- Custom Plumbing: If you're considering adding a second fuel tank to a boat, you may need to add appropriate plumbing to transfer the fuel to the motor or main tank. This could involve running fuel fill lines, vent lines, and fuel transfer lines, as well as installing valves and gauges for monitoring fuel levels. It's important to consult with experts or professionals who can guide you through the specific requirements for your boat.
- Ventilation and Mounting: Proper ventilation and mounting of the auxiliary fuel tank are critical, especially in boats. Ensure that the tank is securely mounted and that all filler and vent hoses are properly installed and accessible. Consider using aluminium tanks with proper "glue" and nylon straps to secure them in place. This will help prevent issues with fumes and abrasion.
Remember, the specific steps and considerations for pumping fuel from the auxiliary tank to the main tank may vary depending on your vehicle type, local regulations, and the auxiliary fuel tank system you choose. Always refer to the instructions provided by the manufacturer of your auxiliary fuel tank and consult with professionals if you have any questions or concerns about the installation or legality of your modifications.
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$1179.99
Use a fixed gas can and a fuel pump
If you're looking to add a second fuel tank to your vehicle, one possible option is to use a fixed gas can and a fuel pump. This method can be a convenient way to increase your fuel capacity, especially if you're planning a long journey or need extra fuel for specific purposes, such as off-road driving. Here are some detailed instructions and considerations to keep in mind:
First, it's important to choose an appropriate fixed gas can. You can either purchase a standard gas can or invest in a purpose-designed long-range fuel tank. The latter option might be more expensive but could offer a more integrated and seamless solution. Consider your objectives and the amount of additional fuel you require to make an informed decision.
Next, you'll need to think about the placement of the gas can. For boats, some people choose to install aluminium tanks above the bottom of the boat, securing them with 5200 plastic strips and nylon straps. For vehicles, you might consider placing the gas can in the storage compartment or finding a custom mount that suits your vehicle's specifications. Ensure that you have adequate ventilation and that the gas can is securely fastened to avoid any potential hazards.
Once you have your gas can in place, you'll need to connect it to your vehicle's fuel system. This is where the fuel pump comes in. You can use the fuel pump to transfer fuel from the gas can to the main tank or directly to the engine. If you're connecting it to the main tank, you'll need to figure out how to valve and switch the lines appropriately. Ensure that you consult a professional or a mechanic if you're unsure about any aspects of the installation.
Additionally, consider any necessary modifications to your fuel pump pressure to ensure compatibility with your setup. You might also want to include a valve connector on your fuel line, allowing you to switch between fuel sources. It's important to note that there aren't many resources available online regarding this method, so further research and consultation with experts in the field may be beneficial.
By following these steps and considerations, you can legally add a second fuel tank to your vehicle using a fixed gas can and a fuel pump. Remember to always prioritise safety and compliance with local regulations when making any modifications to your vehicle's fuel system.
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Frequently asked questions
You can find custom boat fuel tanks online. You can also find second fuel tanks in boating catalogues.
You will need to run a fuel fill line and a vent line. You will also need to run a fuel line back to your motor and tie it to the other by brass valves. You can also plumb the second tank into the original tank with an inline fuel pump.
If you are installing a tank under the deck, ensure that the area is self-venting to prevent the accumulation of fumes. You should also ensure that the tank is secure and will not shift the centre of gravity.
You can redirect your exhaust to put a similar tank on the passenger side. You can also use a fixed gas can or a portable tank.
TransferFlow and SuperTanks sell second fuel tank kits, with the latter offering an OEM replacement tank that holds 60 gallons for a short bed and 75 gallons for a long bed.
