Rajan Wilcox
Mounting a fuel tank to a small engine is a complex process that requires careful consideration of safety and functionality. While some opt for custom-made fuel tanks, others explore cheaper alternatives, such as using a boat fuel tank for a small engine. The process involves marking the mounting locations, drilling holes, and ensuring the fuel supply line is properly connected. Additionally, considerations about the center of gravity and the potential impact of engine heat on fuel temperature are crucial. Safety precautions, such as shielding the driver from fuel and preventing leaks, are also essential.
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What You'll Learn
Ensure the fuel tank is centred and level with the engine
To ensure the fuel tank is centred and level with the engine, you will need to locate and drill mounting holes. This process is typically straightforward, but some holes may be in an awkward position, such as the rear left-hand side of the tank. In such cases, a right-angle drill attachment can be used to drill hole centres, and a die grinder can be used to open the holes to the appropriate diameter.
The fuel filler pipe will also need to be fitted to the tank. This can be done by using a flexible hose that is shortened to the appropriate length and connected to the original metal fuel filler pipe. The metal pipe may need to be cut and twisted to mate with the rubber hose, and the two pieces can be welded together.
Additionally, rubber insulator straps should be applied between the tank and the underfloor, and a liberal application of rubberized asphalt or an equivalent product can be used to mitigate top tank rustout before re-installation.
When centring a fuel tank, it may be necessary to either mount the tank lower or add corrugation to the floor of the boot to facilitate the move. Lowering the tank can help to avoid rust problems where the boot and tank meet. However, this may require modifying and moving the spare tyre mount.
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Disconnect all lines going to the fuel tank
Disconnecting all the lines going to the fuel tank is an important step in removing the fuel tank from your small engine. It is a process that requires careful attention to safety and can be time-consuming, so it is important to be patient and not rush things.
Firstly, you should take a digital photo of the setup before you begin. This will help you to put everything back together in the correct order. Gas tanks have multiple lines, including a fuel supply line, a fill tube, and a vent line. To disconnect the lines, you may need a fuel line disconnect tool, which can be purchased at most auto parts stores. These tools are designed to fit around the fuel line and release the locking mechanism. If you are having trouble removing the lines with the tool, try using a heat gun to warm them up. However, be careful not to get the lines too hot, as this could damage the fuel system.
If your fuel tank has a drain cock, you can drain the gas by loosening the valve. If not, you will need to remove one of the fuel lines to drain the tank. Loosen the clamp on the end of the line connected to the gas tank and pull the hose off. Allow the gas to drain into a container, and store it safely.
In some cases, you may need to remove the rear brake lines before dropping the fuel tank. This is to avoid damaging the brake lines. Additionally, you may need to remove the fuel tank straps that hold the tank in place.
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Remove the fuel tank straps
Removing the fuel tank straps is an important step in detaching the fuel tank from a small engine. Here is a detailed, step-by-step guide on how to do it effectively:
First, it is crucial to understand the setup of the fuel tank straps. Some tanks have multiple straps, with long van tanks often featuring three straps. These straps are usually secured by bolts or fasteners, which may be challenging to remove due to rust or other factors. It is also possible that the straps are riveted in place, requiring a different removal approach.
Before attempting to remove the straps, it is essential to place a jack under the tank to prevent it from dropping to the ground when the straps are detached. Ensure the jack is positioned securely a few inches away from the tank.
Now, let's discuss the process of removing the straps. If the straps are secured with bolts, you can try using a breaker bar, liquid wrench, or a heavy-duty impact wrench to loosen and remove them. In some cases, you may need to cut the straps with bolt cutters or a grinder if they are too tight or inaccessible for standard tools. If you intend to reuse the straps, cutting may not be the best option.
For rusted bolts, additional steps may be required. One method is to use a handheld propane torch to heat up the bolts, making them easier to remove. However, this approach should be handled with caution due to the potential risks associated with heat and gas tanks. An alternative suggestion is to use an inductive heater, which is safer for heating metal near flammable objects.
If the straps are riveted in place, as some users have encountered, there is a different technique to remove them. One effective method involves using a small screwdriver to hammer out the pins that secure the straps in place. By placing the screwdriver through the holes in the mounts, you can push out the pins and release the straps. This approach allows for the reuse of the straps, which is advantageous for those looking to conserve parts.
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Drill holes for the new tank to be bolted into place
To begin the process of drilling holes for the new tank to be bolted into place, you must first mark the mounting locations. It is important to centre punch the locations of the holes to prevent the drill bit from straying away from the desired position. Start by drilling holes with a small bit to create a "pilot hole" for the larger bit. The final hole should be drilled with a bit that matches the bolts you have selected.
Before you start drilling, it is crucial to inspect the undercarriage of the truck bed to ensure there are no other components underneath the hole locations that could be damaged by drilling. This precautionary step helps avoid accidental drilling into your existing fuel tank or any other essential parts.
Additionally, when marking the holes, use a brightly coloured marking tool such as a wax pen or chalk. This helps ensure that you drill the correct holes and avoid any mistakes.
By following these steps, you can accurately drill the holes needed to bolt the new tank securely into place.
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Check for leaks before using the new tank
Checking for leaks before using a new fuel tank is a crucial step to ensure your safety and the proper functioning of your engine. Here are some detailed instructions to guide you through the process:
Firstly, work in a well-ventilated area and ensure there are no sources of flame or spark nearby. Have a fire extinguisher readily available as a safety precaution. Gas is highly combustible, so it is imperative to take these precautions before proceeding.
Now, you can begin the inspection for leaks. One of the most common signs of a leaking fuel tank is the overwhelming smell of gasoline. If you notice a strong odour, it may indicate a leak. However, it is important to note that some vehicles may have better ventilation than others, which can impact the noticeable smell of gasoline.
Another method to check for leaks is to place a piece of cardboard or newspaper beneath the fuel tank. If you notice any gas on the surface below the tank, it confirms a leak. Additionally, you can inspect the area for small puddles, which is another red flag.
You can also observe your fuel gauge. A significant drop, especially when the vehicle has not been in use, could indicate a leaking fuel tank. However, this method may not always be accurate unless a large amount of fuel is being lost.
Furthermore, some fuel tanks have a drain cock at their lowest point. By loosening the valve, you can drain the gas and then inspect for any signs of leakage. If your tank does not have a drain cock, you can disconnect one of the fuel lines, typically the rubber hose at the lowest point of the tank, and allow the gas to drain into a container.
It is also important to consider the impact on engine performance. Leaking fuel due to a damaged hose can cause issues such as misfires, stalling, and hard starting. If you experience any of these problems, it may suggest a leak in the fuel system.
Finally, recall information for your vehicle is essential. Check if there have been any recalls related to fuel tank leaks for your specific model. This information can help determine if the issue is widespread and guide you toward potential solutions. Engine performance and placement are also factors to consider when checking for leaks.
By following these steps and staying vigilant about your safety, you can effectively check for leaks before using your new fuel tank. Remember to consult a professional mechanic if you have any doubts or concerns.
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Frequently asked questions
To mount an auxiliary fuel tank to a small engine, you must first drain the fuel from your old tank. Then, disconnect the fuel lines and remove the fuel tank straps. Center the new tank's centerline with the engine's centerline to prevent having to suck the fuel uphill. Mark the mounting holes, then drill them, ensuring there is space around the tank to prevent it from rubbing against the engine. Finally, bolt the tank into place and connect the fuel supply line.
Work in a clean, well-ventilated area, free of clutter, flames, or sparks. Keep a fire extinguisher nearby and use a digital camera to take pictures of the setup before disassembling it, to help with reassembly.
If your tank has a drain cock, loosen the valve to drain the fuel. If not, drain the fuel by removing one of the fuel lines. Loosen the clamp on the end of the line connected to the gas tank, then pull the hose off and allow the fuel to drain into a container.
A fuel supply line is a tube that carries fuel from the tank to the engine. To connect it, first, determine how and where you will run the line from the tank to the engine. Then, connect the line to the tank and engine, ensuring that the exit is below the tank to prevent siphoning.
If your fuel tank is in a car, you may need to drop the rear suspension and disconnect the rear brake lines before removing the old tank. When installing the new tank, ensure that it is securely fastened with metal straps and that the mounting location complies with safety regulations.
