Regan Brown
Installing two fuel tanks on an outboard engine can provide several benefits, such as increased fuel capacity and reduced refuelling frequency. However, it also comes with certain challenges and considerations. One common method for connecting two fuel tanks is to use a Y or Tee connector to join the supply lines from both tanks, along with a connecting hose between the tanks to maintain equal fuel levels. This setup aims to prevent issues like airlocks and vapor lock, ensuring a consistent fuel supply. Some engines may require modifications, such as adding a remote tank to a gravity-fed engine or installing a fuel pump. It is essential to carefully plan the installation, taking into account factors like tank placement, refuelling procedures, and potential fuel vapors.
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What You'll Learn
Connecting the tanks in parallel
Connecting two fuel tanks in parallel can be done by installing a Blazer or suburban tank in the rear. The tanks can be connected using fittings screwed into the bottom of each tank and then connected with a hose. This setup allows the fuel levels to equalize through the interconnecting hose while the engine draws fuel from one of the tanks. The fuel levels are equalized by gravity, ensuring that both tanks are empty when the engine runs out of fuel.
Another method is to use a dual-circuit ball valve to switch between the two tanks simultaneously. This setup allows for gravity feed from the auxiliary tank into the filler on the main tank. Alternatively, a transfer pump and momentary switch can be used to transfer fuel from one tank to another.
If the tanks are at the same level, the supply lines from both tanks can be joined with a Y-connector, as can the return lines. This plumbing design allows for equilibrium, ensuring that the fuel level on both sides remains the same.
To avoid vapor lock, it is essential to ensure that all air is removed from the lines. Additionally, consider using a soldering iron to attach the flange and clean the tanks thoroughly to eliminate fumes and prepare the metal for soldering.
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Using a Y connector to join supply lines
Connecting two fuel tanks to an outboard engine can be done using a Y connector. This method allows fuel to be drawn from either the internal or external tank. It is important to ensure that the tanks are connected correctly and that the fuel lines are free of air.
One way to connect two fuel tanks in parallel is to use fittings screwed into the bottom of each tank, which are then connected by a hose. This method has been reported to equalize fuel levels perfectly through the interconnecting hose, without the airlock issues that can occur with siphons.
When using a Y connector, it is important to make sure that the tanks are filled to the same level to ensure they empty at the same time. If one tank empties first, it will start sucking air, making the remaining fuel in the other tank unusable.
Some outboard engines have a built-in "Y" valve in the fuel line that allows for a switch between the internal and external tanks. For example, the Mariner 4hp engine has an internal tank and an external connector with a fuel tap that has three positions: one for the internal tank, one for the external tank, and off. By plugging in the external tank and turning the tap to the correct position, you can utilize the external fuel source.
It is worth noting that some engines may not require fuel in the built-in tank and can be connected directly to an external tank or "gerry can." However, specific details about the engine model are necessary to provide a definitive answer.
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Drilling a hole in the cap for an outboard male tank fitting
The next step is to eliminate any remaining fumes. One method is to fill the tank with water, pour gasoline on top, and drain the tank by burning the gasoline. Another method is to fill the tank with carbon dioxide (CO2) or a mix of argon welding gas and CO2. Venting out the fumes is also crucial before proceeding.
After ensuring the tank is free of fuel and fumes, the drilling process can begin. It is recommended to use a hand-operated drill with a hole saw to create the desired hole size. During drilling, use an air compressor to blow away or collect the metal shavings. Greasing the outside of the tank and the hole saw can also help catch the shavings.
Finally, after drilling, it is essential to clean and prepare the tank for welding. Drill a small hole in the corner to drain any remaining water and flush out the metal filings. Weld this small hole shut, and then leak-test the tank. Add a pint of metho or ethanol to absorb any residual water droplets, and then fill the tank with gasoline to test for any issues.
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Using a fuel hose with a priming bulb
The priming bulb is an essential part of the fuel system for outboard engines. It is used to manually prime the fuel supply, unlike car engines, which have an electric fuel pump. The priming bulb consists of a flexible rubber bladder with an inlet and outlet connector on either side. One leads fuel from the tank to the bulb, and the other leads fuel from the bulb to the engine.
When installing two fuel tanks on an outboard engine, a fuel hose with a priming bulb is used to transfer fuel from one tank to another. The hose is connected to the outlet of one tank and the inlet of the priming bulb, with the bulb acting as a siphon to draw fuel from one tank and transfer it to the other. The arrow on the bulb should indicate the direction of fuel flow, with the bulb preferably located downstream of the fuel filters or decanters.
It is important to ensure that the fuel hose is in good condition and alcohol-resistant, especially when using alcohol-gasoline or ethanol-gasoline blends. A collapsed or obstructed fuel hose can cause the engine to stall, leading to expensive damage to the fuel injectors. Therefore, regular maintenance and replacement of the fuel hose and primer bulb are crucial to the proper functioning of the fuel system.
When using a fuel hose with a priming bulb, it is essential to follow the correct procedure. The bulb should be squeezed to create pressure, closing the inlet valve and opening the outlet valve to send fuel to the engine. Releasing the bulb allows it to return to its original shape, creating a vacuum that opens the inlet valve and closes the outlet valve, drawing fuel from the tank into the bulb. This process should be repeated until the bulb becomes harder and the pressure increases, indicating that the fuel system is full and the engine can be started.
By following these steps and maintaining the fuel hose and primer bulb in good condition, you can effectively use a fuel hose with a priming bulb to manage the fuel supply between two tanks in an outboard engine setup.
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Soldering the tanks with a copper soldering iron
When soldering two fuel tanks with a copper soldering iron, there are several important steps to follow. Firstly, ensure that the tanks are cleaned thoroughly to get rid of any fumes and residue, and to prepare the metal surface for soldering. This can be done through various methods, such as steam cleaning, using chemicals, or filling the tank with water to find any leaks. It is important to note that some methods, like steam cleaning, can be dangerous as they may cause gas leaks.
Once the tanks are cleaned, the next step is to choose the right type of solder and flux. A 50-50 lead-tin solder is commonly used, and it is important to ensure that the metal surfaces are free from petroleum products as the solder will not adhere properly. The flux helps prevent oxidation and aids in the soldering process. For steel or cast iron tanks, a flux called Sal-Amoniac is recommended.
When using a copper soldering iron, it is important to heat it remotely to minimise the risk of fire. This can be done by using a small stove or torch to heat the iron before applying it to the area to be soldered. It is crucial to ensure that there are no gasoline vapours left in the tank before introducing an open flame. Additionally, the soldering iron should be clean, and the tip should be shiny to ensure a good solder joint.
Finally, during the soldering process, it is important to heat the area to be soldered and then apply the solder. If the solder does not melt and flow, increase the heat gradually until it does. By heating ahead of the solder, you can work your way along the seam and eventually seal it off. This process requires caution and careful preparation to ensure a strong and safe joint.
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Frequently asked questions
There are several ways to install 2 fuel tanks on an outboard engine. One way is to connect the tanks in parallel using a T or Y connector. Another way is to use a transfer pump and momentary switch to transfer fuel from one tank to the other.
The components needed will vary depending on the method of installation. For the parallel installation, you will need fittings that can be screwed into the bottom of each tank and a hose to connect them. For the transfer pump installation, you will need a transfer pump, a momentary switch, and a dual-port valve.
Yes, there are a few potential issues to be aware of. One issue is that the fuel levels in the tanks may not equalize properly, especially when refuelling. Another issue is that the tanks may need to be filled individually, which can be inconvenient. Additionally, vapour lock and air bubbles may cause issues with fuel transfer.
Yes, installing 2 fuel tanks can provide several benefits. It can increase the fuel capacity of the engine, reduce the frequency of refuelling, and improve the range and endurance of the vessel. Additionally, with proper installation, the fuel levels in the tanks can equalize, ensuring a consistent fuel supply and reducing the risk of running out of fuel during operation.
