Ameer Randolph
Installing an auxiliary fuel tank in your vehicle can be a great way to extend your driving range. While it may be a straightforward process for some, it's important to approach the task with caution and ensure you have adequate space to work. Whether you own a truck or a car, the first step is to determine the placement of the auxiliary tank and ensure it is secure. For trucks, this may involve drilling holes and mounting the tank, while for cars, you may need to consider enclosing the fuel cell or using bladder and foam systems to minimise fumes. It's also crucial to consult experts or mechanics for advice and adhere to legal requirements, especially when modifying fuel systems.
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What You'll Learn
Ensure you have a spacious and safe working environment
When setting up an auxiliary fuel tank, ensuring a spacious and safe working environment is paramount. Before beginning any installation work, it is crucial to make certain that you have ample space to work comfortably and safely. Most accidents and injuries during such projects occur due to cramped spaces, so it is advisable to remove any items inside the vehicle, such as a bed mat, to create a spacious work area.
For diesel truck owners, installing an auxiliary diesel fuel tank can provide extended driving capabilities, especially for long trips. When preparing to install the tank, it is essential to have a high enough rated jack to safely lift the truck. However, it is important to remember never to get under the vehicle when it is only supported by the jack. Always use appropriately sized jack stands, placing them on flat portions of the vehicle's frame for stability.
Additionally, having an extra set of hands can be extremely helpful during the installation process. Lifting and placing the auxiliary diesel fuel tank into the bed of your truck is much easier with assistance. This is especially true when it comes to holding nuts or bolts in place as you tighten them from either the bottom or top of the auxiliary truck bed fuel tank.
When it comes to placement, it is important to position the auxiliary fuel tank away from the sides, front, and back of the bed. This ensures that there is some space on all four sides of the tank to prevent it from rubbing against any part of the truck bed, which could potentially damage the tank. By taking these precautions and creating a spacious and safe working environment, you can help ensure a smooth and successful installation of your auxiliary fuel tank.
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Consider the fumes and frequency of refuelling
When installing an auxiliary fuel tank, it is important to consider the fumes and the frequency of refuelling.
Firstly, fumes can be dangerous and cause health issues, so it is important to ensure proper ventilation in the space where the auxiliary fuel tank is installed. This can be achieved by creating a second enclosure for the fuel cell or by using bladder and foam systems to contain any potential leaks. Installing a rubber mat between the battery pack and the auxiliary tank can also help to minimise fumes.
Additionally, the frequency of refuelling should be considered. If you anticipate needing to refuel frequently, it may be more convenient to install a larger auxiliary fuel tank or choose a location that is easily accessible for refuelling. This can reduce the number of stops required during long trips.
To further reduce the frequency of refuelling, consider improving the fuel economy of your vehicle. At higher speeds, fuel economy may decrease, so adjusting driving habits or vehicle settings can help optimise fuel efficiency. Additionally, regular maintenance and proper tyre inflation can also improve fuel economy.
Finally, it is important to consider the refuelling process itself. Manual refuelling methods, such as using a jerry can, can be time-consuming and may not be feasible for larger auxiliary fuel tanks. In such cases, consider installing a fuel transfer pump system to facilitate faster and more efficient refuelling.
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Prepare the vehicle by lifting and supporting it
When preparing to install an auxiliary fuel tank, it is important to ensure that your vehicle is securely lifted and supported to provide a safe and stable workspace. Here are the steps you should follow:
First, make sure you have a high enough rated jack to safely lift your vehicle. It is crucial to use a jack that is specifically designed and rated for your vehicle's weight. Do not attempt to lift the vehicle with an inadequate jack as it can lead to dangerous situations.
Once you have the appropriate jack, carefully lift the vehicle following the manufacturer's instructions. Place the jack on flat portions of the vehicle's frame to ensure stability. Remember, safety should always come first. Do not, under any circumstances, position yourself under the vehicle when it is only supported by the jack.
After lifting the vehicle, you must now support it securely with appropriately sized jack stands. Place the jack stands on the same flat portions of the vehicle's frame as the jack. Ensure that the jack stands are stable and capable of bearing the weight of the vehicle. This step is crucial to creating a safe workspace.
Now that the vehicle is securely lifted and supported, you can proceed with the auxiliary fuel tank installation. Remember to have a helper assist you with the installation, as an extra set of hands can make the process much easier and safer.
By following these steps, you can safely prepare your vehicle for the installation of an auxiliary fuel tank. Always prioritize safety and ensure that you have the necessary equipment and assistance before proceeding.
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Place the tank, allowing space on all four sides
When placing the auxiliary fuel tank, it is important to allow some space on all four sides of the tank. This is to prevent the tank from rubbing against any part of the truck bed, which could potentially damage the tank. It is also crucial to have enough space to work and move freely during the installation process, as most accidents and injuries occur when individuals are cramped for space.
Before drilling holes in the truck bed for mounting the tank, it is recommended to first place the tank in the desired location. This will help ensure that the tank is installed away from the sides, front, and back of the bed. Mark the holes where the tank will be mounted, taking into account the placement of the mounting tabs on the tank.
For trucks with rubber plugs near the bottom of the stake pocket support posts, removing these plugs provides access to the bottom side of the truck bed. After creating a hole in the centre of the rubber plug, insert the rubber fuel line, and then run the line towards the factory fuel neck. This will allow you to place the auxiliary fuel tank in position and use bolts, nuts, and washers to securely fasten it in place.
It is beneficial to have an extra set of hands when positioning and securing the auxiliary fuel tank. This additional assistance can help with holding nuts or bolts in place while tightening them from either the bottom or top of the auxiliary truck bed fuel tank.
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Mark holes, fasten the tank, and insert the fuel line
When installing an auxiliary fuel tank, safety should be the top priority. Ensure you have a large enough workspace and that your vehicle is securely supported. Now, let's dive into the steps of marking holes, fastening the tank, and inserting the fuel line:
Mark Holes and Fasten the Tank:
First, decide on the placement of your auxiliary fuel tank. It's important to choose a location that allows for some space on all four sides of the tank to prevent it from rubbing against the truck bed. Once you've found the perfect spot, mark the holes where you'll install the tank. Most auxiliary fuel tanks come with mounting tabs located on the bottom edges, or on the bottom and taller back edges for taller tanks that are more prone to tipping over.
Now, it's time to fasten the tank securely. On trucks, you might have access to the bottom side of the truck bed by removing rubber plugs near the bottom of the stake pocket support posts in the corners. If so, remove the plug, cut a hole in its center, insert the rubber fuel line, and then replace the plug. Run this line towards the factory fuel neck. Next, use bolts, nuts, and washers to fasten the fuel tank in position. Having an extra pair of hands can be helpful at this stage to hold the nuts or bolts in place while you tighten them from either the bottom or top of the auxiliary truck bed fuel tank.
Insert the Fuel Line:
If you're using an inline fuel filter, remember to prime it before installation by removing the filter and filling it with diesel fuel. Additionally, if you're planning to use an auxiliary tank as your primary fuel source, you might need to make some modifications. One method is to splice the line and use a switch and a 6-port valve to control the fuel flow. However, be cautious when dealing with returned fuel, as you don't want it mixing back into the regular fuel in the OEM tank. Systems like Greasecar offer separate valves to manage this process more effectively.
Remember, the steps outlined above provide a general guide, and specific procedures may vary depending on your vehicle's make and model. Always refer to manufacturer instructions or seek advice from professionals for a safe and successful auxiliary fuel tank installation.
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Frequently asked questions
Always ensure you have enough 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 the jack. Make sure the vehicle is supported with appropriately sized jack stands placed on flat portions of the vehicle's frame.
You should place the auxiliary fuel tank in the location where it will be installed before drilling holes in your truck bed. Make sure to install the tank away from the sides, the front, or back of the bed. Leave some space on all four sides of the tank to prevent it from rubbing against the truck bed and causing potential damage.
All auxiliary fuel tanks come with mounting tabs located on the bottom edges. For taller tanks that are more prone to tipping over, the mounting tabs may be on the taller back edges as well. Use bolts, nuts, and washers to fasten the fuel tank in position.
You can splice the line further back and add a 6-port valve and a switch. You can also use the factory fuel gauge to read from the auxiliary tank. Alternatively, you can use separate valves and flip the switches manually to allow the system to purge.
Enclose the fuel cell in a second enclosure or consider bladder and foam systems to minimize fumes. Install a rubber mat between the battery pack and the auxiliary tank. If you have a hatchback, you can choose the biggest off-the-shelf auxiliary tank that fits and slide it in, covering it with a cargo cover.
