Rajan Wilcox
Auxiliary fuel tanks are a great way to extend your vehicle's driving range and provide peace of mind during emergencies. Installing an auxiliary fuel tank can be done in a few simple steps, but it's important to ensure that it is done properly and safely. Before beginning the installation process, it is crucial to have a spacious working area and remove any items inside the truck bed. The placement of the auxiliary fuel tank should allow for some space on all four sides to prevent potential damage to the tank or the truck bed. Mark the mounting locations and use a center punch to create pilot holes before drilling to avoid straying from the desired location. When drilling, ensure you don't hit any other items under the truck bed, such as the existing fuel tank. Consider the fuel system configuration, whether it's gravity-fed or pump-based, and determine how to run the fuel supply line from the auxiliary tank to the main fuel tank. Some systems use a switch in the cab to change tanks, while others may require a separate fuel pump. Additionally, check your local laws regarding gravity-fed auxiliary fuel tanks, as some states have specific regulations.
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What You'll Learn
Gravity feed vs pump: Pros and cons
There are several factors to consider when deciding between a gravity feed and a pump system for an auxiliary fuel tank.
One advantage of a gravity feed system is its simplicity, with some users reporting that there is "hardly nothing to break or go wrong with it". It is also a cost-effective option, as it does not require the purchase and installation of additional components such as a pump. Additionally, a gravity feed system can free up space in the vehicle, as there is no need for a pump mechanism.
However, a gravity feed system may result in a slower transfer of fuel compared to a pump system. This could be a significant consideration for those who require quick refuelling. Additionally, the use of gravity feed systems may be restricted by local laws in certain states or areas, so it is important to check the regulations in your region.
On the other hand, a pump system offers faster refuelling capabilities and may be more suitable for those who require quick and efficient refuelling. Pump systems can also provide more control over the flow of fuel, allowing for precise measurements and the ability to stop the flow when needed.
However, a pump system introduces additional components that may require maintenance or repairs. The pump itself takes up space and may be inconvenient for those who utilise a bed cover, as one user mentioned. Additionally, the use of a pump may require a return line to the deck tank to accommodate any excess fuel that the engine does not use.
Ultimately, the decision between a gravity feed and a pump system depends on specific needs and local regulations. Both options have their advantages and disadvantages, and it is essential to carefully consider these factors before making a choice.
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Safety considerations
Safety should be a key consideration when making an auxiliary fuel tank. Here are some important safety precautions to keep in mind:
Fuel Tank Design and Construction
Firstly, ensure your fuel tank complies with regulations. Fuel tanks must be clearly and permanently marked with the manufacturer's name, manufacture date, gallon size, and a statement indicating compliance with FMCSA (Federal Motor Carrier Safety Administration) requirements. The tank should have a non-spill air vent, such as a ball check valve, and at least two sources of vents to prevent overpressure. The fuel connections from the auxiliary tank to the primary system should not interfere with the primary system's functions and should be of an equal or larger size for adequate fuel flow.
Installation and Placement
When installing the auxiliary fuel tank, consider its placement carefully. Most auxiliary tanks are installed in the bed of the truck, but under-bed options are also available. Ensure that the tank's weight does not compromise the vehicle's handling or towing capabilities. Proper installation and balancing are critical for safety. Additionally, consider the size and shape of the tank, especially if you're towing a fifth wheel or similar equipment.
Fuel Transfer and System Compatibility
Understand the fuel transfer process and ensure compatibility with your vehicle's system. Some individuals opt for gravity-fed systems, but these are illegal in some regions due to the risk of overfilling and leaks, which can pose a fire hazard. If using a gravity-fed system, ensure it complies with local regulations. Alternatively, you can use a separate fuel pump to transfer fuel from the auxiliary tank to the OEM tank. Be mindful of fuel type compatibility as well; mixing certain fuels can have undesirable effects.
Maintenance and Regular Checks
Auxiliary fuel tanks require regular maintenance and checks to ensure they remain in proper working condition. Regularly inspect for leaks, check fittings, and clean the tank as necessary. This is crucial for preventing fuel leaks, which can pose safety and environmental hazards. Additionally, consider cycling out the fuel in your auxiliary tank periodically to prevent fuel degradation and maintain fuel quality.
Legal Compliance
Finally, be sure to research and adhere to local and state laws governing the installation and use of auxiliary fuel tanks. Requirements may vary depending on your region, and non-compliance can lead to legal issues. Understand the specific regulations related to gravity-fed systems, fuel types, and modifications to the fuel system. Stay informed about any updates or changes to these regulations to ensure your setup remains legal and safe.
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Installation steps
The first step in installing an auxiliary diesel fuel tank is to ensure you have sufficient space to work. Most accidents and injuries occur when individuals are cramped for space and unable to move freely. Remove any items inside the bed of the truck, such as a bed mat, to create a spacious working area. It is also recommended to have an extra set of hands to assist with lifting the tank, reducing the load and preventing any scrapes or scratches to the truck's finish.
Next, determine the placement of the auxiliary fuel tank. It is important to install the tank away from the sides, front, and back of the bed, leaving some space on all four sides. This prevents the tank from rubbing against the truck bed and potentially causing damage. Once you have determined the ideal location, mark the holes where the tank will be installed using a brightly coloured marking tool such as a wax pen or chalk. This ensures that you drill the correct holes and do not damage any other components.
After marking the mounting locations, remove the auxiliary diesel fuel tank from the pickup bed. As a precautionary measure, use a centre punch on the marked locations to prevent the drill bit from straying. Begin drilling with a small bit to create a "pilot hole" before switching to a larger bit. The final hole should be drilled with a bit that matches the size of the bolts you plan to use. Before drilling, inspect the undercarriage of the truck bed to avoid drilling into your existing fuel tank or any other critical components.
Before bolting the new tank into place, plan the route of the 3/8" rubber fuel supply line from the auxiliary tank to the existing factory fuel tank. At this stage, you can also consider the type of fuel feed system you want to use. There are two main options: gravity feed and pump-based. A gravity feed system is generally considered simpler and more reliable, as it has fewer failure points and no risk of fuel overflow. On the other hand, a pumped system allows you to run the fuel through filters to polish it before it enters the main tank.
Finally, bolt the auxiliary tank into place, ensuring it is securely attached to the truck bed. If desired, you can add a manual valve to control the flow of fuel from the auxiliary tank. Additionally, you can install a fuel gauge to monitor the fuel level in the auxiliary tank.
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Cost of parts
The cost of parts for an auxiliary fuel tank varies depending on the type of tank, its capacity, and the specific parts required. Here is a breakdown of the potential costs:
Tank Capacity and Type:
Auxiliary fuel tanks come in different capacities, typically ranging from 37 gallons to 100 gallons or more. The cost of the tank will depend on its size and type (auxiliary vs refuel tank). For example, TransferFlow offers an 82-gallon refuel tank for $654, while a 75-gallon auxiliary tank with the Trax II system costs about $1,100.
Valves, Plumbing, and Wiring:
Adding valves, plumbing, and wiring to your auxiliary fuel tank can increase the cost significantly. These parts are necessary for the proper functioning and safety of the fuel system. The exact cost will depend on the specific valves, pipes, and wiring required for your setup.
Fuel Gauge and Sending Unit:
Some auxiliary fuel tanks may require a separate fuel gauge, which can add to the cost. Additionally, you may need to purchase a sending unit to accurately measure the fuel level in the tank.
Switching Unit and Selector:
If you want to switch between multiple fuel tanks, you will need a switching unit and an in-cab selector. These parts allow you to choose which tank is currently in use. The cost of these components can vary depending on the specific setup and vehicle.
Mounting Hardware and Straps:
When installing an auxiliary fuel tank, you will need appropriate mounting hardware and straps to secure the tank in place. These parts may be included with the tank purchase or may need to be sourced separately, impacting the overall cost.
It's important to note that the cost of parts can vary depending on your location, the specific vehicle, and the complexity of the auxiliary fuel tank system you choose to install. It is always recommended to consult with professionals or experienced individuals to ensure a safe and proper installation.
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Fuel tank kits
The RDS Diesel Install Kit for Auxiliary Diesel Fuel Tanks is one such example, compatible with a range of Ford, Dodge, Chevrolet, and GMC trucks. This kit enables a gravity-feed system, allowing fuel to flow from the auxiliary tank into the primary fuel tank. It is a legal option for diesel vehicles and includes the necessary valves and fittings to angle the drain pipe conveniently.
Another option is to purchase an auxiliary tank with a Trax II system, which offers a more sophisticated solution for around $1,100. This system likely includes additional features and functionality compared to the basic gravity-feed system.
For those seeking a more cost-effective solution, it is possible to build your own auxiliary fuel tank setup. This DIY approach may require purchasing individual components separately, such as a sending unit, a switching unit, and an incab selector. However, it allows for customization and can be achieved for under $300, as mentioned by a user who successfully implemented such a system in their Ford diesel truck.
When considering fuel tank kits, it is important to keep in mind any state and local laws that may apply to auxiliary fuel tanks and their installation. Some states have specific regulations regarding gravity-fed aux fuel tanks, so it is essential to ensure compliance with the relevant authorities.
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Frequently asked questions
A gravity feed system is trouble-free and worry-free, with no pump, wiring, or switches to worry about. Once installed, it's set and forget.
With a pumped fuel system, you can run fuel through filters to polish it before putting it into your main tank.
Make sure you have plenty of space to work and remove any items inside the bed of the truck. Do not get under the vehicle when it is only supported by a jack. All vehicles must be supported by appropriately sized jack stands.
Consider the cost of the kit, the capacity of the tank, and whether it includes all the necessary valves, plumbing, and wiring. Also, check if the kit is compatible with your vehicle's fuel system.
First, ensure you have enough space to work and remove any items from the truck bed. Then, place the tank in the desired location, marking the holes for installation. After marking the holes, remove the tank and drill pilot holes before drilling the final holes with a bit that matches your bolts. Finally, determine how and where to run the fuel supply line from the tank to the factory fuel tank.
