Sylvie Willis
There are several ways to have an external fuel tank fill the main tank. One way is to manually fill the main tank from the external tank as needed, either by opening and closing a valve or using a separate fuel pump to transfer the fuel. Another method involves setting up the external tank to provide fuel directly to the engine, which may require complex modifications. Additionally, some vehicles have the option to use gravity to transfer fuel from the external tank to the main tank. It is important to consider local laws and regulations regarding auxiliary fuel tanks and fuel systems, as they may vary across different states and countries.
| Characteristics | Values |
|---|---|
| Distance of the external tank from the engine | 20 metres maximum |
| Level of the external tank | Same level as the engine |
| Space in the tank | Leave at least 5% free to prevent spillage |
| Filling external tanks mid-air | Transfer fuel into pylon-mounted external tanks |
| Filling a boat's fuel tank | Place the fuel saver over the vent |
| Filling a portable tank | Place the tank on the ground |
| Auxiliary tank as primary | Manually fill the OEM tank from the aux tank |
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What You'll Learn
- Install a supply line and return line to feed the generator set directly from an external tank
- Use a Holley fuel pump to transfer fuel from the auxiliary tank to the OEM tank
- Use a backseat tank, filling through the window, and draining by gravity into the main tank
- Place the external tank within 20 metres of the engine and on the same level
- Ensure compliance with regulations governing the installation of fuel tanks in the country of installation
Install a supply line and return line to feed the generator set directly from an external tank
To install a supply line and return line to feed a generator set directly from an external tank, there are several key considerations and steps to follow. Firstly, the design of the fuel system should be specific to the characteristics of the installed generator set and its components. This includes taking into account the quality, temperature, pressure, and necessary volume of the fuel, as well as preventing any air, water, impurities, or humidity from entering the system.
Clean fuel storage and transfer tanks are essential for the proper functioning of the generator set. These tanks should be periodically emptied to drain any decanted water or sediment, and long storage periods should be avoided. It is also important to control the temperature of the fuel, as excessive temperature increases can reduce fuel density and lubricity, impacting the generator's performance.
When installing the supply and return lines, it is recommended to maintain a clearance between the lines to prevent fuel heating and to stop impurities from entering the engine. This distance should be as wide as possible, with a minimum of 50 cm between the lines. Additionally, the lines should be installed as close to the bottom of the tank as possible, maintaining a distance of no less than 5 cm.
To prevent air from entering the system when the fuel level drops, the storage tank supply line should be installed as deep as possible. It is also crucial to leave a free space of at least 5% in the tank during filling to prevent spillage due to fuel expansion. The fuel storage tank should be located as close to the engine as possible, with a maximum distance of 20 meters, and both should be at the same level.
Furthermore, to prevent fuel overflow, a non-return valve can be installed at the genset's fuel inlet, especially if there is a difference in level between the genset and the external tank. This setup ensures that the fuel system functions effectively and safely, providing a direct feed from the external tank to the generator set.
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Use a Holley fuel pump to transfer fuel from the auxiliary tank to the OEM tank
One option for transferring fuel from an auxiliary tank to the OEM tank is to use a Holley fuel pump. This can be done manually by opening and closing a valve or by running a separate fuel pump to transfer the fuel from the auxiliary tank to the inlet tube of the OEM tank.
One user on the Ford Truck Enthusiasts Forum reported using a Holley fuel pump and a switch on their dashboard to transfer fuel from their 91-gallon auxiliary tank to their OEM tank. They noted that this method is particularly useful in emergencies and for having extra fuel on hand in case of earthquakes or other natural disasters that could disrupt local services.
Another option mentioned in the forum is to use an Auto Fuel Controller (AFC) system, which automatically fills the main tank from the auxiliary tank while driving. The AFC monitors the stock OEM fuel tank and turns on a transfer pump when the stock tank reaches around a quarter full. The transfer pump is then turned off by the AFC when the stock tank is nearly full or the auxiliary tank is empty.
When using a Holley fuel pump to transfer fuel from the auxiliary tank to the OEM tank, it is important to consider local laws and regulations regarding gravity-fed auxiliary fuel tanks. Some states and localities may have specific requirements or restrictions on the use of such systems.
Additionally, it is worth noting that modifying the fuel system to allow the auxiliary tank to pump fuel directly into the engine may be illegal in certain jurisdictions, such as California. Therefore, it is crucial to consult the relevant regulations and seek professional advice before making any modifications to the fuel system.
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Use a backseat tank, filling through the window, and draining by gravity into the main tank
Using a backseat tank that can be filled through the window and drained by gravity into the main tank is a possible method for filling external fuel tanks. This method is suggested in a discussion on Reddit about installing an auxiliary fuel cell. The user suggests that the fuel pump should be accessible from under the rear seat, allowing for easy refuelling. By building a backseat tank, the user can fill it through the window and then open a valve to allow the fuel to drain into the main tank. This setup also keeps the mass between the axles.
The same user also suggests welding a cage to hold the tank in place and installing a firewall to protect the user in the event of a fire. Other users in the discussion suggest enclosing the fuel cell in a second enclosure or using bladder and foam systems for safety. One user mentions that installing a rubber mat between the battery pack and the auxiliary tank can help minimise fumes, especially in a hatchback.
It is important to note that the discussion is centred around modifying cars for a "cannonball" event, where teams attempt to drive across the United States as quickly as possible. As such, the focus is on maximising speed and minimising refuelling stops. While these modifications may be suitable for this specific event, they may not be necessary or advisable for general use.
Additionally, it is worth considering the potential safety hazards and legal implications of modifying a vehicle's fuel system. It is always recommended to consult with professionals and adhere to local regulations when making significant alterations to a car's fuel system.
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Place the external tank within 20 metres of the engine and on the same level
When installing an external fuel tank, it is important to consider the placement of the tank in relation to the engine. One crucial guideline to follow is to place the external tank within a distance of 20 metres from the engine. Keeping the tank close to the engine ensures easier accessibility and more efficient fuel transfer.
It is also recommended that the external tank be placed on the same level as the engine. By maintaining the same level, you eliminate the need for complex plumbing and fuel transfer mechanisms. Gravity can be utilised to facilitate the flow of fuel from the external tank to the main tank or directly to the engine. This setup simplifies the process and reduces the chances of fuel leaks or blockages caused by complex plumbing configurations.
The placement of the external tank within 20 metres of the engine and on the same level contributes to a more streamlined and efficient fuel system. This arrangement not only ensures the functionality of the fuel transfer but also enhances the overall aesthetics of the setup by maintaining a clean and organised appearance.
To achieve this optimal placement, careful planning and measurement are required. It is essential to consider the available space around the engine and select an appropriate location for the external tank that adheres to the distance and levelling guidelines. Additionally, ensuring easy access to the external tank for refuelling or maintenance purposes should be a key consideration in the placement process.
By following these guidelines and carefully planning the placement of the external tank, you can establish a functional and efficient fuel system that complements the design of your vehicle or setup. Remember to refer to local laws and regulations regarding auxiliary fuel tanks to ensure compliance and safety.
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Ensure compliance with regulations governing the installation of fuel tanks in the country of installation
Ensuring compliance with regulations governing the installation of fuel tanks is essential for safety and environmental protection. Here are some detailed instructions to ensure compliance with fuel tank installation regulations in a given country:
Understand the Regulatory Landscape
Research and understand the specific regulations that govern fuel tank installations in the country of installation. These regulations may be outlined by the Environmental Protection Authority (EPA), the Occupational Safety and Health Administration (OSHA), or other relevant agencies. Different countries have varying EPA regulations regarding the storage and maintenance of fuel. For example, the US EPA has specific regulations for underground storage tanks (USTs), while the UK has safety regulations like the Control of Pollution (Oil Storage) (England) Regulations.
Identify the Type of Fuel Tank
Identify whether the fuel tank is an underground or aboveground storage tank, as regulations may differ for each type. For instance, in the US, the EPA has specific UST regulations that focus on preventing releases, operator training, delivery prohibition, and secondary containment.
Comply with Design and Construction Standards
Ensure that the fuel tank system is properly designed and constructed according to industry codes and standards. For example, the EPA requires UST systems to be designed and constructed to prevent corrosion and protect against combustion, following nationally recognized codes of practice.
Register and Inspect the Fuel Tank
Register the fuel tank with the appropriate authorities, as required by the regulations. For instance, regulated storage tank systems in Florida must be registered with the Department of Environmental Protection (DEP). Regularly inspect the fuel tank to ensure compliance with safety regulations and maintain proper maintenance. Inspections may include checking for leaks, corrosion, and proper functionality.
Maintain Records and Documentation
Maintain detailed records and documentation to demonstrate compliance with the regulations. Keep records of leak detection performance, maintenance activities, inspections, and any other relevant information. These records should be readily available for review by inspectors or auditors.
Implement Safety Precautions and Emergency Measures
Follow safety precautions, such as proper ventilation and distance from ignition sources, to prevent accidents and hazards. Develop and implement detailed emergency response plans to address fuel spills, leaks, or other potential incidents.
By following these instructions and staying informed about the specific regulations in the country of installation, you can ensure compliance with the governing laws and maintain a safe and environmentally responsible fuel tank installation.
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Frequently asked questions
You can manually fill the main tank from an external tank by opening and closing a valve or using a separate fuel pump to transfer the fuel.
It is recommended to locate the external tank as close to the engine as possible, at a maximum distance of 20 metres. The tank should be placed on the same level as the engine.
Yes, certain states and countries have specific laws and regulations regarding the use of external fuel tanks. It is important to research and comply with the relevant laws in your area.
