Rajan Wilcox
Installing a second fuel tank can be a complicated process, and it is important to consider safety at all times. The process will vary depending on the type of vehicle and the location of the tank. For example, installing an auxiliary fuel cell in a car involves different steps compared to adding a second fuel tank to a boat. In general, you will need to consider the fuel supply and return pipes, as well as any necessary valves or pumps to facilitate the transfer of fuel between the tanks.
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What You'll Learn
Use a steel firewall to separate the fuel tank
Installing a second fuel tank in your car can be achieved through the use of a steel firewall. This method involves creating a barrier to separate the fuel tank from the rest of the vehicle's interior. Here are the steps and considerations for this process:
Firstly, it is important to understand the purpose and benefits of a firewall. In automotive engineering, a firewall, or bulkhead, is designed to separate the engine compartment from the passenger compartment. In the context of a second fuel tank installation, a firewall ensures the fuel tank is isolated and sealed off from the interior of the vehicle. This provides safety and peace of mind.
When constructing the steel firewall, it is recommended to use 18-gauge steel. This thickness of steel provides the necessary strength and protection. You may need to fabricate two panels for easier installation, ensuring they fit securely in the desired location. It is crucial to properly seal the panels with a high-quality seam sealer to prevent any fuel leaks.
Additionally, consider reinforcing the steel firewall with bracing or using a bead roller to create ribs for added strength. This extra step can enhance the overall stability and safety of the installation.
By installing a steel firewall, you are not only complying with safety regulations but also gaining peace of mind. In the event of a collision or impact, a properly installed steel firewall will help contain the fuel tank and reduce the risk of fuel-related incidents. It is a crucial safety measure that should not be overlooked.
Lastly, keep in mind that a steel firewall can also offer additional benefits, such as reducing engine noise in the passenger compartment and providing secure storage space when leaving your vehicle unattended. It is a versatile modification that enhances both safety and functionality. Always ensure your vehicle modifications comply with local regulations and safety standards.
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Connect the pipe from the additional tank to the return line
Connecting the pipe from the additional tank to the return line is a crucial step in installing a second fuel tank. Here's a detailed guide on how to approach this task:
Firstly, it's important to understand the basic setup of the fuel system. The fuel supply line leaves the tank at its lowest point and connects to the fuel pump or engine. There is also a large fill tube, known as the fuel filler pipe, which is connected to the gas fill entry point. When installing a second fuel tank, you will need to cut the fuel filler pipe and add a "tee" or "T connector" that will connect to the auxiliary tank's inlet. This will allow both tanks to fill simultaneously.
Now, let's focus on the return line connection. One common concern is the potential for return fuel to flow back into the secondary tank instead of the main tank. To address this, consider installing a non-return valve in the pipe connecting the two tanks. This valve will prevent fuel from flowing back into the secondary tank. Another suggestion is to use a purpose-built electric fuel pump, which can be switched on when the main tank needs refuelling from the auxiliary tank.
When connecting the pipe from the additional tank to the return line, ensure that all connections are secure and tight to avoid any leaks. It is also important to consider the positioning of the tanks and the length of the pipes to ensure that fuel can flow effectively between them.
Additionally, some vehicles may have specific requirements or variations in their fuel systems. For example, certain vehicles may have a fuel level gauge for the main tank, while others may not. In the latter case, it is recommended to have an overflow pipe from the main tank to the secondary tank to prevent overfilling. This overflow pipe can also be utilised for filling the secondary tank after the main tank is filled.
Remember, safety should always be a top priority when working with fuel systems. Ensure you are working in a well-ventilated area and have a fire extinguisher nearby. It is also beneficial to take photographs of the setup before making any adjustments, as this can serve as a reference during the installation process.
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Use a Y or T connector to avoid affecting the flow of return fuel
When installing a second fuel tank, one of the key considerations is how to connect the additional tank to the existing fuel system without disrupting the flow of return fuel. One effective method to achieve this is by utilising a Y or T connector.
The Y or T connector offers a strategic solution by providing a junction point where the pipe from the secondary fuel tank can be seamlessly integrated into the return line. This configuration ensures that the return fuel has multiple pathways to flow back to the main tank without obstruction.
However, it is important to be mindful of potential challenges. In some cases, return fuel may exhibit a tendency to flow back into the secondary tank, particularly if there is any resistance between the connector and the tank. This phenomenon can be mitigated by incorporating a non-return valve in the transfer pipe, strategically positioned just before the connection with the return pipe.
By installing a non-return valve, you can effectively prevent return fuel from flowing back into the secondary tank. This ensures that the return fuel consistently flows towards the main tank, maintaining the intended direction of fuel flow. It is a crucial step to ensure the efficient and proper functioning of the dual fuel tank setup.
In conclusion, employing a Y or T connector is a viable approach to integrate a second fuel tank without impacting the flow of return fuel. By understanding the potential challenges and incorporating appropriate solutions, such as a non-return valve, you can ensure a seamless and effective dual fuel tank configuration. This setup will provide you with the benefits of extended fuel capacity and improved range, all while maintaining the optimal performance of your vehicle's fuel system.
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Fit another fuel feed to the filler pipe
To fit another fuel feed to the filler pipe, you will need to first locate the fuel filler neck. This is a solid piece of tubular steel that joins the fuel filler inlet and the rubber fuel hose on the gas tank. Once located, you will need to remove the mounting screws or bolts attached to the cutaway. You can then remove the fuel filler cap cable from the fuel neck and place it aside.
The next step is to locate the fuel tank. Go under the vehicle and look for the fuel tank. Place a transmission jack or similar jack under the fuel tank and loosen and remove the straps to the fuel tank. Lower the fuel tank slightly to gain access to the vent hose attached to the fuel tank. Remove the clamp and small vent hose.
Now, you will need to cut the fuel filler pipe and splice in the new fuel feed. Some people recommend cutting the metal fill pipe and removing it before splicing, while others suggest splicing into the filler vent hose to avoid cutting the metal pipe. If you do cut the metal pipe, be careful of metal shavings falling into the pipe and down into the tank. You can drill out the rivets in the fuel door and loosen the hose clamps on the fuel tank to pull out the filler neck. Drill a hole in the filler neck and weld on a hose barb fitting. You may also need to drill a hole in the vent tube and weld on a hose barb for the vent/return line back to the auxiliary tank.
Finally, wash out the tube with hot soapy water and flush it several times to remove any residue or filings from grinding/drilling. You can then connect the new fuel feed to the filler pipe and secure it with hose clamps. Ensure that all connections are tight and secure to prevent any fuel leaks.
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Use a gravity feed or an electric pump to transfer fuel
When installing a second fuel tank, you have the option to use a gravity feed or an electric pump to transfer fuel. Both methods are effective, but they have different advantages and considerations. Here are some detailed instructions and insights for each approach:
Gravity Feed System
A gravity feed system relies on the force of gravity to transfer fuel from a higher elevation to a lower one. To set up this system, the source tank needs to be securely positioned at a higher level than the receiving tank. Gravity will then naturally allow the fuel to flow downwards. This method has a long history of predictable performance and is relatively easy to install and maintain. It is also preferred by some due to its simplicity, requiring only one fuel line and a few wires for the solenoid. Additionally, a gravity feed system does not introduce the possibility of overfilling the tank, as can happen with electric pumps.
However, it is important to ensure that all connections are tight and secure to prevent leaks. A valve should be used to control the flow and prevent overfilling. This system is suitable for stationary setups where the tanks can be permanently positioned with elevation differences.
Electric Pump System
Electric pumps offer convenience and can make refilling easier. They are typically controlled by a switch mounted inside the vehicle, allowing you to refill the tank as you drive. When selecting an electric pump, consider factors such as capacity, material, and safety features. Steel tanks, for example, are durable and suitable for heavy-duty use, while polyethylene tanks are lightweight and resistant to corrosion. Look for tanks with features like fire screens and vented caps. Ensure the tank is stable, properly grounded, and free of leaks. Regular maintenance and inspection of the tank and pump are necessary to ensure safety and proper functioning.
Electric pumps can be more expensive than manual options, and there is a risk of overfilling if not properly monitored. To mitigate this risk, consider installing a return line to direct any excess fuel back into the auxiliary tank.
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Frequently asked questions
You should install the second fuel tank in the trunk of your car and make a steel firewall behind the back seat.
You can add a non-return valve to the transfer pipe to prevent return fuel from flowing into the secondary tank. Alternatively, you can fit another fuel feed into the tank or the filler pipe.
You can use gravity or an electric pump to transfer fuel from the secondary tank to the main tank.
