Ameer Randolph
There are several ways to convert two small fuel tanks into one. One way is to use a transfer pump and a momentary switch to connect the two tanks. Another way is to use a dual-circuit ball valve to switch between the two tanks. A third option is to use an equalizing line between the two tanks, which will allow fuel to be drawn from both tanks simultaneously. Additionally, one can cut a tank and weld on end caps to create multiple tanks for different purposes, such as carrying diesel fuel, coolant, or hydraulic oil.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Fuel tank conversion | Dual fuel tanks to single fuel tank |
| Fuel tank types | Auxiliary, OEM, main, gravity feed, dual-circuit ball valve |
| Fuel tank connection | Equalizing line, Y connector, transfer pump, manual dual port valve, Tee or Wye |
| Fuel gauge | Single gauge indicating the level of both tanks |
| Fuel transfer | Controlled by the user, transfer pump, jet pump, fuel filler pipe |
| Fuel level | Equilibrium between tanks, maintained by connecting vent lines |
| Fuel refill | Both tanks must be refilled simultaneously to maintain equal fuel levels |
| Leak detection | Fuel smell, visible leak, fuel gauge discrepancy |
| Safety | Potential fire hazard due to leaks |
| Maintenance | Regular checks for leaks and proper functioning of pumps and valves |
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What You'll Learn
Use a Y connector to join supply lines
Using a Y-connector to join supply lines is a convenient way to connect two appliances to a single propane tank. This setup is ideal for camping, allowing you to run a stove and a lantern, or any other combination of devices, from the same fuel source. This method is not about coupling two tanks together but rather drawing fuel from one tank to power multiple appliances.
When it comes to fuel lines, you'll typically find copper pipes or flexible hoses used to transport fuel from the tank to the engine. Some vehicles use a combination of both, with a short run of copper pipe extending from the tank and then flexible hoses to the engine. The flexible lines could be made from rubber or plastic, and the joins between copper and flexible pipes are usually secured with jubilee clips.
While copper is a common choice for fuel lines, it does have some drawbacks. Copper is susceptible to work hardening, which is the ease at which it fractures when subjected to vibration. This can be an issue in certain engine setups. Additionally, in the event of a fire, copper pipes can melt, dumping fuel into the hottest part of the fire and exacerbating the situation.
As an alternative to copper, some people consider using nylon for fuel lines. However, this is not recommended due to safety concerns. In the event of a fire, nylon will melt, releasing the fuel and potentially intensifying the blaze. It's important to prioritize safety and follow industry standards when selecting materials for your fuel lines.
When joining fuel lines, it's crucial to use the correct fittings and hoses. The type of hose you need will depend on your vehicle's specifications, such as engine size and whether it uses a carburettor or fuel injection. For example, older, smaller-engined cars with carburettors typically use 6mm hoses, while larger engines may require 10mm hoses. Fuel-injected cars often use 12mm or 15mm hoses from the tank to the pump. It's important to measure the internal diameter when sizing the hose.
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Use a manual dual-port valve to switch between tanks
Using a manual dual-port valve is a convenient way to switch between two small fuel tanks. This setup allows you to have a main tank and an auxiliary tank, with the ability to draw fuel from either tank as needed. The dual-port valve acts as a switching mechanism, controlling the flow of fuel from one of the two tanks to the engine.
To set up this system, you will need to install a dual-port valve between the fuel tanks and the engine. This valve will have two inlets, each connected to one of the fuel tanks, and a single outlet leading to the engine. You can then use a toggle or rocker switch to manually control which tank is currently active and supplying fuel.
It is important to note that this type of setup is not suitable for all vehicles. For example, it should not be used in vehicles with in-tank fuel pumps or pumps located between the tanks and the valve. Additionally, it is not recommended for marine applications or systems with fuel return lines.
By incorporating a manual dual-port valve into your fuel system, you gain the flexibility to switch between tanks while driving. This can be particularly useful if you are travelling long distances or want to ensure you always have a reserve supply of fuel.
Overall, using a manual dual-port valve to switch between two small fuel tanks offers a straightforward and effective solution for those seeking a simple and inexpensive dual-tank setup.
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Cut and weld tanks to make three smaller tanks
Welding fuel tanks can be extremely dangerous, with the possibility of igniting fuel vapors. Before cutting and welding the two small fuel tanks, there are several safety precautions that must be taken to avoid injury or death. First, ensure that all power sources are off by disconnecting the battery and setting the ignition to the off position. This will reduce the chance of a spark igniting any fuel in the tank. Next, drain the fuel tank of any remaining fuel and place it in an approved gas container designed for flammable liquids. Avoid performing this step over or near inspection pits.
After the tank is drained, it is important to clean and neutralize the tank to remove any remaining fuel or vapors. One method is to fill the tank with water and a lot of dish soap, then drop an air line in on a trickle to bubble out the tank. After an hour, drain the tank and check for any remaining fuel by observing if more bubbling is required. Another method is to drill a small hole in the tank, plug the tank, and put in enough acetone to slosh around when the tank is rolled. Then, drain and blow-dry the tank with compressed air. It is safe to weld once all the gas smell is gone.
Once the tanks are cleaned and neutralized, you can begin the process of cutting and welding. It is recommended to have professional welding experience or consult a professional welder before attempting to cut and weld fuel tanks. When cutting the tanks, use a tool such as an oxy acetylene torch to cut the tanks into three equal or desired sizes. After cutting, weld the tanks together to form three smaller tanks. Ensure that the welds are strong and leak-free by testing the integrity of the welds. Place a small amount of fuel in the new tanks and check for any leaks. If the tanks are leak-free, you can reattach any necessary components following the manufacturer's specifications.
By following these steps and taking the necessary safety precautions, it is possible to cut and weld two small fuel tanks to make three smaller tanks. However, it is important to prioritize safety and consult professionals when dealing with flammable liquids and materials.
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Use a transfer pump to move fuel from one tank to another
Using a transfer pump to move fuel from one tank to another is a straightforward process, but there are a few things to keep in mind to ensure it is done safely and effectively. Firstly, it is important to choose the right type of fuel transfer pump for your specific application. There are various types of transfer pumps available, including electric diesel transfer pumps, battery-powered pumps, and hand fuel pumps. Electric pumps are suitable for static fuel tanks with access to mains power, while battery-operated pumps are necessary for mobile refuelling without access to mains power. If you are transferring diesel from a drum or in small amounts, a manual hand fuel pump may be the most cost-effective option.
Next, you should consider the flow rate required for your setup. The flow rate is measured in litres per minute and will determine how quickly the fuel is transferred. The larger the volume of fuel you need to transfer, the longer it will take, so choosing a suitable flow rate is essential. You can purchase ready-to-use diesel transfer pump kits that include a nozzle and hose, or you can install a pump into an existing system. If you are working with diesel and AdBlue, it is important to note that you will need separate pumps as AdBlue requires pumps made with non-corrosive materials such as stainless steel or polypropylene.
Additionally, safety should be a top priority when working with fuel. It is crucial to be able to detect any fuel leaks promptly. With a transfer pump, you can shut off the pump as soon as you notice any signs of a leak, such as the smell of fuel or a visible trail or puddle on the ground. This level of control is not possible with a gravity feed system, where a leak may go unnoticed until it is too late.
Finally, when using a transfer pump to combine two small fuel tanks into one, it is important to carefully monitor the fuel transfer process. Ensure that the filler and vent of the auxiliary tank flow downhill to avoid issues. You can also use a low-pressure fuel gauge or a flow meter to track the fuel transfer and ensure that all the fuel has been moved to the main tank. By following these steps and considerations, you can effectively and safely use a transfer pump to convert two small fuel tanks into one.
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Use a tee connector to join two tanks
Using a tee connector is a simple and inexpensive way to join two fuel tanks into one. This method is useful if you want to install an auxiliary fuel tank in your vehicle to increase its range. The first step is to cut the fuel filler pipe and add a tee connector that will join the main tank and the auxiliary tank inlets. This will allow both tanks to be filled simultaneously.
To transfer fuel from the auxiliary tank to the main tank when the main tank gets low, you will need to install a fuel pump. The fuel can be pumped into the main tank's vent line via another tee connector. This setup gives you control over the fuel transfer, allowing you to turn it on and off as needed. It is important to note that you should ensure the filler and vent of the auxiliary tank flow downhill to avoid issues.
One advantage of using a tee connector and a fuel pump is that you can avoid the need for a hole in the bottom of the tanks. This can be achieved by using an internal tie, such as the one used in Subaru's saddle tanks. An internal tie can also be used for self-priming, which is worth researching. Additionally, a small electric pump can be used to detect leaks, as it can be shut off if a leak is detected.
However, it is important to consider the potential drawbacks of this setup. Having an additional pump increases the chances of failure. Additionally, a fuel leak may empty both tanks, depending on how it is set up. Therefore, it is crucial to monitor for leaks by regularly checking for trails or the smell of fuel. Overall, using a tee connector to join two fuel tanks is a straightforward and cost-effective method, but it requires careful consideration and monitoring to ensure safe and proper functionality.
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Frequently asked questions
You can convert two small fuel tanks to one by plumbing them together with a Y connector or a dual-circuit ball valve. This will allow you to maintain the same fuel level in both tanks and draw fuel from one tank.
Converting two small fuel tanks to one can simplify your system and reduce potential issues associated with having two tanks and a transfer pump. It can also increase your fuel capacity and provide a more consistent fuel supply.
One potential issue is that you will need to add fuel to both tanks simultaneously during refueling to maintain equal fuel levels. Additionally, converting the tanks may require modifications to the fuel gauge to ensure it reads properly.
The parts required may vary depending on your specific setup, but you will generally need a connector, such as a Y connector or a dual-circuit ball valve, to join the supply and return lines of the tanks. You may also need additional components, such as a manual dual-port valve, to control the fuel flow and maintain equal fuel levels.
Yes, it is important to consider the potential risks associated with fuel leaks, especially when using a transfer pump. Ensure that you have a way to detect leaks promptly and take the necessary precautions to minimize fire hazards.
