Mercedes Mullins
There are a variety of ways to connect a fuel transfer tank to a truck fuel tank. Some methods include using a hose to siphon the fuel, employing a hand pump, or utilising a gravity feed system by mounting a second tank and connecting the two tanks with hoses. Other options involve purchasing a refueling tank system, which comes with the necessary components for installation, or installing a custom dual-fuel tank setup. It is important to consider factors such as legality, safety, and vehicle compatibility when choosing and implementing a connection method.
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What You'll Learn
Using a hose to siphon fuel
First, find a suitable gas canister or closed container to siphon the fuel into. It is important to use a closed container to prevent hazardous gasoline fumes and the risk of spilling. Ensure the canister has sufficient volume to hold the amount of fuel you plan to siphon.
Next, obtain a length of clear plastic tubing, approximately 1 inch (2.5 cm) in diameter. This tubing will serve as the siphon hose. Check that the tubing is free of any obstructions before you begin.
Now, locate the fuel port on your truck's fuel tank. You may need to use a small piece of PVC pipe or a modified funnel to access the port, especially if your tank has an anti-theft flap or an anti-siphon barrier. Some tanks have a fuel cap that can be removed to access the fuel directly.
Place your gas canister on the ground near the opening of the truck's fuel tank. This positioning utilizes gravity to assist the siphoning process. Feed the tubing into the truck's fuel tank, ensuring that one end of the tube is fully submerged in the fuel. Be cautious not to inhale any fumes during this step.
To check if the tube is submerged, carefully blow into it and listen for the sound of bubbles. You may need to cut the end of the tube at a sharp angle and rotate it as you insert it into the tank to navigate any flaps or valves. Ensure the other end of the tube remains in your empty gas canister.
Once the tubing is in place, the siphoning process will begin. Gravity will cause the fuel to flow through the tube and into your gas canister. Keep the tube lower than the level of fuel in the tank to maintain the flow. If you need to stop the siphoning, simply remove the tubing from the fuel tank, being careful not to spill any fuel.
Remember to always exercise caution when handling gasoline, and ensure proper ventilation to avoid inhaling harmful fumes.
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Installing a fuel transfer pump
Plan the Setup:
Before beginning the installation, it's important to plan the setup by considering the type of vehicle, the size and placement of the fuel transfer tank, and the routing of fuel lines. Determine if you will be using a gravity feed system or a pump-assisted system.
Choose the Right Components:
Select a fuel transfer tank that suits your vehicle and fuel capacity needs. Consider the available space and the amount of fuel you require. Choose a fuel pump that is compatible with your vehicle, such as a 12-volt or diesel-only electric fuel pump. Ensure you have the necessary hoses, connectors, valves, and gauges for a secure and leak-free system.
Mount the Fuel Transfer Tank:
Securely mount the fuel transfer tank in your vehicle, ensuring it is stable and won't slide around. Consider placing it under the spare tire area or in the truck bed. Follow the manufacturer's instructions for proper mounting procedures.
Connect the Fuel Lines:
Use fuel-compatible hoses to connect the fuel transfer tank to the vehicle's fuel tank. Cut the fuel filler pipe and add a "tee" or "T-connector" to allow fuel to flow between the tanks. Ensure that all connections are secure and sealed to prevent leaks.
Install the Fuel Pump:
Install the fuel pump according to the manufacturer's instructions. If using a gravity feed system, mount the pump between the two tanks with hoses at the bottom for fuel flow and at the top for air movement. If using a pump-assisted system, connect the pump to the power source, such as the car battery.
Test and Monitor the System:
Once the installation is complete, test the system by filling the transfer tank and ensuring that fuel is transferred properly to the vehicle's tank. Regularly monitor the fuel levels in both tanks and be aware of any potential issues, such as fuel sucking air if one tank becomes empty while the other is full.
It is important to note that fuel transfer and storage come with inherent risks, and it is the user's responsibility to ensure their setup complies with local laws and safety regulations. Always exercise caution when working with flammable liquids.
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Gravity feed systems
From a vehicle performance standpoint, gravity feed systems can negatively affect federally mandated, manufacturer-implemented, on-board vehicle diagnostic systems. In newer vehicles, a gravity-fed system may keep the main fuel tank overfull, resulting in a diagnostic trouble code and the check engine light remaining on. This can be a nuisance and cause drivers to miss valid vehicle issues.
Additionally, safety concerns with gravity feed systems go beyond spilling fuel during normal operation. If the transfer fuel hose is damaged, the fuel will continue to flow until the transfer tank is empty, creating a hazardous condition and potentially violating the 1990 Clean Air Act. Furthermore, the overfill tendencies of gravity-fed systems may lead some users to seal the rollover OEM valve, which could result in fuel leakage in the event of a rollover.
Despite these potential issues, some users still opt for gravity feed systems for their convenience. When setting up such a system, it is recommended to always have a ball valve installed directly into the tank before running the fuel line. Additionally, some users suggest using a solenoid with a backup valve in case the tank needs to be removed or there is a line failure.
It is important to note that the legality of gravity feed systems is unclear due to regulatory ambiguity. While they can be convenient, it is crucial to carefully consider the potential vehicle performance and safety implications before installing such a system.
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Using a fuel tapper
Fuel tappers can also be used in the opposite way, to fill a tank. For example, you can drain a generator and use the fuel in a lawnmower, and then fill the generator with fresh gas.
You can also use a small battery-operated pump, combined with a hose, to transfer fuel. This can be charged using your car battery.
If you are using a hose to transfer the fuel, you can put your vehicle on an elevated parking spot, with the jerry can below the tank. Use the hose to siphon the gasoline. You can use a hand pump if you do not want to suck the gas. Once the hose fills up, gravity will take over, taking the gas from the high elevation to the lower elevation.
It is important to note that the fuel lines in your car are supposed to be under pressure. If you put them back together incorrectly, you could set your car on fire.
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Aftermarket refueling tank systems
Transfer Flow, a prominent manufacturer in this market, offers a range of refueling tank systems with capacities ranging from 40 to 109 gallons. Their products are designed to fit various truck models, including light-duty and heavy-duty trucks, and can accommodate most over-the-rail toolbox configurations. The 40-gallon refueling tank system, for example, fits under most tonneau covers and is compatible with all light and heavy-duty trucks.
The refueling tank systems from Transfer Flow come with all the necessary components for installation. This includes a 12-volt pump, a 12-foot fuel hose with a nozzle, a fuel cap, a wire harness with a dash-mounted power switch, and the required hardware. The tanks are also powder-coated for a durable finish, ensuring they can withstand the elements.
In addition to Transfer Flow, there are other aftermarket fuel tank system manufacturers that offer similar products. These systems aim to provide extended driving ranges and reduce the need for frequent fuel stops. When considering an aftermarket refueling tank system, it is important to ensure that the product complies with the legal requirements of your state or country.
Frequently asked questions
There are several ways to connect a fuel transfer tank to your truck's fuel tank. One way is to use a gravity feed system, where you mount a second tank and connect the two tanks with a hose at the bottom for the fuel to flow, and another hose at the top for air to move in and out. You can also use a transfer pump, which you can buy for as little as $4. Another option is to modify the top of the fuel pump housing/tank with a T or valve, and then connect a hose with a valve to the transfer tank.
It is important to consider the legality of your setup. For example, in the US, a HUT sticker and IFTA sticker are required. You should also be aware of the potential for fuel to spill in the event of a rollover, and take steps to prevent this.
You can use a 12-volt GPI pump, which comes with Transfer Flow refueling tank systems. Another option is the Diesel-only electric fuel pump sold by Advance Auto for $65.
When transferring fuel to your truck's tank while driving, the truck's fuel gauge may not read accurately. To avoid this, you can use the aux tank's fuel sender and wire in a gauge, or use a low-pressure fuel gauge to read the line pressure during the transfer.
