Mercedes Mullins
There are several ways to make a second fuel tank pumpless. One way is to mount the second tank and connect the two tanks with hoses at the top and bottom. The hose at the bottom allows gas to flow in and out, while the hose at the top allows air to move in and out. This setup uses gravity to feed gas into the engine and does not require a secondary pump. Another method is to use a Y connector to join the supply lines of both tanks, allowing fuel to be drawn from both tanks simultaneously and maintaining equilibrium between them. However, this method may require refuelling both tanks simultaneously to avoid fuel imbalance. It is important to consider the legalities and safety hazards, such as fire risks, when modifying fuel tanks.
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What You'll Learn
Use gravity to feed fuel from the second tank
To make a second fuel tank pumpless, one method is to use gravity to feed fuel from the auxiliary tank to the main tank. This setup typically involves mounting the second tank higher than the main tank and connecting the two tanks with hoses. One hose allows the fuel to flow downwards from the auxiliary tank to the main tank, while another hose at the top enables air movement in and out, preventing a vacuum from forming.
There are several considerations for this pumpless system. Firstly, ensure that the vent lines of both tanks are tied together to prevent fuel backup and stalling issues. Additionally, a simple ball valve or petcock can be used to control the fuel flow into the main tank. For safety, it is recommended to “refuel” while stopped and to include a check valve to prevent fuel leakage in the event of a rollover.
While gravity feed systems have been restricted to diesel vehicles in the past due to safety concerns, they are not inherently illegal. However, it is important to check the latest regulations and ensure your setup complies with them. Some manufacturers produce gravity feed fuel tanks for gasoline-powered vehicles, so it is possible to find compliant solutions.
When designing your pumpless system, consider adding a fuel filter between the auxiliary and main tanks to ensure clean fuel transfer. Additionally, be mindful of the tank's filler pipe design, as it may affect the filling process. Some users recommend keeping the valve open while driving and closing it when parked to prevent heat expansion issues and potential leakage.
Overall, a gravity feed system for a second fuel tank can be a simple and effective solution, but careful planning and adherence to safety regulations are crucial.
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Plumb the two tanks together for a larger fuel supply
Plumbing Two Fuel Tanks Together for a Larger Fuel Supply
Plumbing two fuel tanks together can provide a larger fuel supply, but there are several factors to consider. Firstly, it is important to ensure that the tanks are at the same level to maintain equilibrium and allow fuel to flow evenly between them. This can be achieved by mounting the tanks securely and connecting them with hoses or pipes.
One method is to use a ""Y" connector to join the supply lines from both tanks, as well as the return lines, while connecting the vent lines between the tanks. This setup allows for a balanced fuel level in both tanks, as indicated by the dash gauge. However, it is important to address potential refuelling challenges. When refuelling, both tanks need to be filled simultaneously to maintain equal fuel levels. Failing to do so may result in fuel imbalance, and the fuel gauge will only indicate the level of the tank with the sensor.
To overcome this issue, a tube can be installed between the tanks at their lowest point. This tube helps maintain equal fuel levels in both tanks, even when traversing rough terrain. Additionally, a manual dual-port valve can be incorporated to switch between the two tanks. It is also essential to consider the location of the pickup tube and the direction of fuel flow. A one-way check valve can be employed to ensure fuel flows in the desired direction, preventing overfilling.
When plumbing the tanks together, it is crucial to avoid drilling holes in the top of the tanks, as this may expose the fuel line to damage and increase the risk of emptying both tanks. Instead, consider using a transfer pump to refill one tank from the other. This method involves using one tank as the primary source and refilling it from the secondary tank when necessary. Remember to assess the legalities and safety considerations associated with dual fuel tank setups, especially regarding potential leak risks.
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Use a transfer pump to move fuel from the aux tank to the main tank
Using a transfer pump is a popular method to move fuel from the aux tank to the main tank. This method is especially useful when setting up a dual-fuel tank system for long-term expedition travel. The process involves installing an additional fuel tank, usually from another vehicle, and connecting it to the main tank using fuel lines and a transfer pump.
One approach is to cut the fuel filler pipe and add a "tee" that connects to the aux tank inlet. This ensures that both tanks fill simultaneously. A transfer pump is then added to transfer fuel from the aux tank to the main tank when needed. The fuel is pumped into the main tank's vent line via another tee. This method provides flexibility and control over fuel usage.
To enhance this setup, consider incorporating a fuel gauge or a low-pressure fuel gauge to monitor fuel levels during the transfer. Additionally, ensure that the filler and vent of the aux tank flow downhill to avoid potential issues. Remember to shut off the transfer pump manually when the transfer is complete, as the pump may continue running even after the aux tank is empty.
It is important to note that some vehicles have in-tank fuel pumps that are prone to failure. In such cases, it may be beneficial to convert the in-tank pump to an external inline pump, making it more accessible and easier to replace. This modification can be achieved by cutting through the main fuel pipe and fuel pump wires and installing an external pump.
By employing a transfer pump to move fuel from the aux tank to the main tank, you can achieve a functional dual-fuel tank system. This setup offers the advantage of extended fuel capacity and the ability to manage fuel usage efficiently. However, always ensure that you comply with legal requirements and safety precautions when installing and operating such systems.
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Ensure fuel levels are equal in both tanks
To ensure fuel levels are equal in both tanks, you can try the following methods:
Firstly, you could connect the tanks with a tube or hose at the bottom to allow the fuel to flow in and out. This method, known as a "gravity feed", only requires one pump or return and is used in thousands of tractors. It is important to note that the tanks should be at the same level for this to work effectively.
Another option is to mount one tank higher than the other and let it gravity feed into the lower tank. This method also only requires one pump, with the fuel supply drawn from the bottom tank and the return line running into the top tank.
Additionally, you could consider plumbing the two tanks together with a Y-connector for the supply and return lines, as well as connecting the vent lines. This will allow for equilibrium between the tanks, maintaining the same fuel level in both.
It is worth noting that when refuelling, you will need to fill both tanks simultaneously to ensure equal fuel levels. If only one tank is filled, the fuel will not equalize between the two.
Finally, some people have suggested using a transfer pump and momentary switch to connect the tanks, or installing a dual-circuit ball valve to switch between them. These methods may require additional research and consideration of your specific setup.
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Use a dual tank fuel pump kit for vehicles with two fuel tanks
If you have a vehicle with two fuel tanks, you can use a dual tank fuel pump kit to avoid having to use a secondary pump. This is a useful option if you are looking to avoid the hassle and cost of having to remove and replace a faulty internal pump.
The dual tank fuel pump kit is designed for vehicles with two fuel tanks and contains everything you need to complete your dual tank fuel system. The kit includes a motorized valve that switches the fuel feed, the return, and the fuel level. This type of kit is legal for sale and use on various vehicles, including Emissions Controlled Vehicles, Uncontrolled (Non-Emissions Controlled) Vehicles, and Racing Use Only Vehicles, as it does not affect vehicle emissions and is exempt from emissions regulations.
Some vehicles, such as the Citroen Picasso, are fitted with an in-tank fuel pump that is prone to failure, especially when using waste vegetable oil mixes or biofuel. These internal pumps can be challenging and costly to replace, requiring you to jack up the car, drain the fuel, remove various components, and pull out the fuel tank. By using a dual tank fuel pump kit, you can avoid these issues and benefit from the kit's reliability and ease of maintenance.
Additionally, having two pumps provides benefits such as redundancy in the event of a pump failure. With two pumps, you can always pull fuel from the second tank if one pump fails. Furthermore, having a pump close to each tank can reduce the strain on the pump and minimize the noise produced.
Overall, the dual tank fuel pump kit offers a comprehensive solution for vehicles with two fuel tanks, providing reliability, ease of maintenance, and peace of mind.
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Frequently asked questions
Mount the second tank and connect the two tanks with a hose at the bottom for the gas to flow in and out, and a hose at the top for air to move in and out. This is a straight gravity feed that does not require a secondary pump.
You can cut the fuel filler pipe and add a "tee" that will go to the aux tank inlet.
Add a tube between the two tanks at the lowest level.
You get a roll-over valve, and there is one less pump that can fail.
Potential issues include the filling of the auxiliary tank after the main tank fills up, and the possibility of fuel overflow if the vehicle is parked on a side slope. Additionally, filling both tanks can take a long time if they are connected by a single filler neck.
