Ameer Randolph
Hooking up multiple fuel tanks to a truck is a complex process that requires careful planning and execution. It is important to consider the placement of the tanks, the type of fuel, and the method of connecting the tanks to ensure the system functions properly and safely. One common method is to use a 'T' connector to tie the tanks together, but this can cause issues if one tank runs out of fuel before the other. Another option is to drill holes and run fuel lines between the tanks, but this requires careful measurement and consideration of the existing fuel system. In either case, it is crucial to have a working fuel gauge and sender to monitor fuel levels and prevent running out of fuel unexpectedly.
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What You'll Learn
Tying dual fuel tanks together
One challenge with tying dual fuel tanks together is refuelling, as it requires filling both tanks simultaneously to maintain equal fuel levels. If only one tank is filled, the fuel may not transfer to the other tank, resulting in imbalanced fuel levels. To address this issue, some individuals suggest installing a tube between the tanks at their lowest level to facilitate equal fuel distribution. However, this modification may introduce potential snag points when navigating rough terrain.
Another consideration when tying dual fuel tanks together is the fuel gauge accuracy. In some cases, the fuel gauge may only function for one of the tanks, typically the rear tank, making it challenging to determine the fuel level in the other tank. Troubleshooting and repairing the fuel gauge or sending unit can help address this issue.
It is worth noting that tying dual fuel tanks together may not be legal for gasoline engines, but it is generally permitted for diesel engines. Additionally, certain vehicles, such as older 18-wheelers, were designed with this setup, pulling fuel from one tank and returning it to the other. Modern vehicles often pull and return fuel to both tanks simultaneously.
When considering tying dual fuel tanks together, it is important to assess the specific vehicle's configuration, fuel system, and any legal requirements. Consulting with a professional or experienced individuals in forums can provide valuable insights into the feasibility and potential modifications required for a successful implementation.
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Using a Y connector to join supply lines
To achieve this, the supply lines from each tank can be joined together with a Y connector, creating a single fuel supply from both tanks. Additionally, the return lines can also be connected using a Y connector, allowing for a continuous flow of fuel between the tanks. This setup ensures that the fuel level is equalised, preventing one tank from running out of fuel before the other.
However, it is important to consider the potential challenges associated with this method. One key challenge is the refuelling process. When using a Y connector, it is necessary to add fuel to both tanks simultaneously during refuelling. If only one tank is filled, the fuel may not flow between the tanks, resulting in an imbalance. This can be addressed by adding a tube between the tanks at the lowest level, allowing for equal fuel distribution.
Another consideration is the fuel gauge accuracy. When tying fuel tanks together with a Y connector, the fuel gauge may only indicate the level of fuel in one of the tanks, typically the rear tank. This can make it challenging to determine the exact fuel level in each individual tank.
Overall, using a Y connector to join supply lines is a viable option for connecting multiple fuel tanks in trucks. It helps maintain fuel equilibrium and ensures a continuous fuel supply. However, it is important to carefully consider the potential challenges, such as refuelling logistics and fuel gauge accuracy, when implementing this method.
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Mounting an auxiliary tank
First, determine the appropriate location for the auxiliary tank. Some popular locations include under the bed of the truck, in the wheel well, or under the frame of the vehicle. When choosing a location, consider accessibility for refuelling and maintenance, as well as ensuring that the tank is securely mounted and does not interfere with other components.
Next, it is essential to select the right type of auxiliary tank for your truck. The tank should be compatible with the fuel type (diesel or gasoline) and have sufficient capacity to meet your needs. Ensure that the tank is made from durable materials, such as aluminized steel, to withstand the weight of the fuel and the conditions of the road.
When installing the auxiliary tank, it is crucial to follow the manufacturer's instructions and adhere to safety guidelines. This may involve connecting the tank to the vehicle's fuel system, including supply lines, return lines, and vent lines. Consider using a Y-connector or a T-connector to join the supply and return lines of the tanks, ensuring that the fuel level remains equal in both tanks.
Additionally, it is important to address the issue of water condensation in the tank. Water is heavier than diesel, so it will sink to the bottom of the tank and contaminate your fuel. To mitigate this, consider installing a fuel pump on top of the tank with a draw tube that stops a few inches short of the bottom, preventing the transfer of water and sediment to your main tank. Alternatively, keep the fuel tank full to prevent condensation from forming inside the tank.
For safety purposes, consider enclosing the auxiliary tank in a second enclosure or exploring bladder and foam systems to minimize fumes. Installing a rubber mat between the battery pack and the auxiliary tank can also enhance safety.
Finally, regular maintenance and monitoring of your auxiliary tank are crucial. Ensure that you refuel both tanks simultaneously to maintain equal fuel levels and avoid potential snags when driving through rough terrain. Keep an eye on fuel gauges and consider fixing or replacing senders if they are not working properly.
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Drilling holes for installation
Drilling holes for the installation of fuel tanks in trucks requires careful planning and execution to ensure a safe and proper setup. Here is a step-by-step guide on how to approach the drilling process:
Planning the Installation:
Before drilling any holes, it's crucial to plan the placement of the auxiliary fuel tank(s) in the truck bed. Ensure that the tank is positioned away from the sides, front, and back of the bed, allowing space on all four sides. This spacing prevents the tank from rubbing against the truck bed and causing potential damage. Mark the desired locations for the holes that will be used for installing the tank.
Drilling the Holes:
- Center Punch: After marking the mounting locations, remove the auxiliary fuel tank from the truck bed. Use a center punch on the marked locations to create a small indentation. This helps guide the drill bit and prevents it from straying from the desired spot.
- Pilot Hole: Start drilling with a small-sized bit to create a pilot hole. This initial hole guides the larger bit and ensures accuracy.
- Final Hole: Select a drill bit size that matches the bolts you plan to use. Drill the final hole at the marked locations. Exercise caution and inspect the undercarriage of the truck bed before drilling to avoid drilling into critical components, such as the existing fuel tank or other essential parts.
Running the Fuel Lines:
Before bolting the new tank into place, determine the routing of the fuel supply line from the auxiliary tank to the factory fuel tank. Typically, this involves drilling another hole in the truck bed and threading the fuel line down to the factory tank filler neck. Alternatively, some trucks provide access to the bottom side of the truck bed by removing rubber plugs near the stake pocket support posts, allowing the fuel line to be inserted and routed.
Mounting the Tank:
With the holes drilled and the fuel lines prepared, it's now time to mount the auxiliary fuel tank. Place the tank in position and use bolts, nuts, and washers to securely fasten it in place. Having an extra pair of hands during this step can be helpful to hold the nuts or bolts as you tighten them from either the bottom or top of the auxiliary tank.
Remember to consult vehicle-specific instructions and adhere to safety guidelines when performing any modifications or installations involving fuel tanks and lines.
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Using a fuel transfer pump
Hooking up three fuel tanks to a truck requires a fuel transfer pump. Here is a step-by-step guide on how to do it:
Step 1: Choose the Right Transfer Tank and Pump
Firstly, you need to select an appropriate transfer tank that fits your truck's specifications. Transfer tanks come in various shapes and sizes, such as L-shaped or rectangular designs, and can be made from materials like steel or aluminium. Ensure that the transfer tank is DOT-approved and legal for the type of fuel you intend to use (gasoline, diesel, kerosene, methanol, etc.).
Along with the transfer tank, you will need to choose a suitable fuel transfer pump. Transfer pumps can be optional add-ons or built into the tank. Transfer Flow and GPI are popular brands that offer a range of fuel transfer pumps. Consider the pump's capacity and compatibility with your tank and fuel type.
Step 2: Install the Transfer Tank and Pump
The installation process may vary depending on the specific products you've chosen. Carefully follow the manufacturer's instructions for the transfer tank and pump installation.
Some general considerations during installation include:
- Mounting the transfer tank securely in your truck, ensuring it is stable and doesn't move during transit.
- Connecting the transfer tank and the main fuel tank with hoses and fittings. You may need to cut and modify existing fuel filler pipes to accommodate the new setup.
- Installing the fuel transfer pump, ensuring it is securely attached and connected to the power source (typically 12V or 12-volt GPI).
- Setting up a switch in the cab to control the transfer pump, allowing you to turn it on and off as needed.
Step 3: Test and Monitor the System
Once the transfer tank and pump are installed, thoroughly test the system to ensure it functions correctly.
- Pay close attention to fuel levels during the initial tests to avoid overfilling.
- Monitor the fuel gauge readings in both the main and auxiliary tanks to ensure accuracy. The truck's fuel gauge may not read accurately during fuel transfers, so be cautious to avoid overfilling.
- Check for any leaks or drips during and after the testing process. Some transfer pumps have a hose purge feature to prevent fuel drips.
Step 4: Maintain and Service the System
Regular maintenance and servicing are essential to keep your fuel transfer system operating safely and efficiently:
- Inspect the transfer pump and valve for any signs of wear or rust and replace them as necessary.
- Ensure that all connections and fittings are secure and tight to prevent leaks.
- Refer to the manufacturer's recommendations for specific maintenance tasks and intervals.
By following these steps and staying mindful of safety precautions, you can successfully hook up three fuel tanks to your truck using a fuel transfer pump.
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Frequently asked questions
First, you need to decide on the placement of the auxiliary diesel fuel tank. It should be away from the sides, front, and back of the bed to prevent the tank from rubbing against any portion of the truck bed. Mark the holes where you will install the tank and then remove the tank from the pickup bed. Use a center punch to prevent the drill bit from straying, and drill the holes. Before drilling, check the undercarriage of the truck bed to avoid drilling into your existing fuel tank or another important item.
After drilling, you can bolt your new tank into place. Determine how and where you will run the rubber fuel supply line from the tank to your existing factory fuel tank.
When refueling, you will need to add fuel to all tanks. If you only fill one tank, the fuel will not go up the draw tube and back down into the other tanks. You could run out of fuel in one tank if you do not add fuel to all of them. You can add a tube between the tanks at the lowest level to maintain an equal amount of fuel in all tanks.
