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Old 05-07-2015, 12:28 AM   #1
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build a second fuel tank so complete 69gal

First of all sorry for some faults, i am german and not a language genius
For our forthcoming overland trip crossing Africa i decided that the 46 gallon fuel tank is not enough. So i built an second tank fits in the driver side where often the propane tank is mounted. (I removed mine as i hate propane and use fuel for heating and cooking) There is also a under floor storage mounted so built one in behind the axle was no option for me.
The size of the new tank is around 23 gallons. I rebuilt the original filler to an "Y" so i can fill both tanks using the original port. I meditate long time how is the best way to get the fuel from the second tank to the engine and decided that i will not make change at the "original" 46gal tank and sometimes the most simple way could be the best.
So the funktion:
I installed an second fuel pump ( so i have also a spare pump mounted at the car if i would need it in any time ). After i used 2/3 of the fuel in the big tank i switch on the pump and the fuel from the smaller tank will go to the bigger one. This takes about 20min and a control light is reminding me not to forget to switch of the pump after the process is completed.
I also built in 2 pre filters into the system. One is for the original tank and one is for the second. So i also have the possibility -in case of very bad fuel- to filter it 2 times before going to the engine. I use one Racor PS120-2 filter and one equal from Delphi. (it is much easier to get it here in Germany). As the Delphi have built in also an magnetic Filter i decided to built also an Magnet into the Racor as i like the idea.

Here some pics from the building process as pictures maybe easier to understand than stupid translated words ....

welding the tank:

tank with the holding frame (mounted to the structure of the body)

clamps to fix it on the holding frame
Attached Thumbnails
IMGP3085 (2).jpg   IMGP3107 (2).jpg   IMGP3092 (2).jpg  
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Old 05-07-2015, 12:32 AM   #2
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Re: build a second fuel tank so complete 69gal

Cut the original filler and weld it to a self made "Y"

build in Y-filler > here conected to the original tank, waiting for the second

Built in second tank
Attached Thumbnails
IMGP3098 (2).jpg   IMGP3106 (2).jpg   IMGP3142 (2).jpg  
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Old 05-07-2015, 12:41 AM   #3
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Re: build a second fuel tank so complete 69gal

both filters

fuel pump ( no worry, i changed the wiring after testing)
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IMGP3144.jpg   IMGP3145.jpg  
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Old 05-07-2015, 05:24 AM   #4
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Re: build a second fuel tank so complete 69gal

Nice work.

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Old 05-07-2015, 08:06 AM   #5
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Re: build a second fuel tank so complete 69gal

Wow, amazing job!
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Old 05-07-2015, 05:48 PM   #6
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Re: build a second fuel tank so complete 69gal

Impressive
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Old 05-08-2015, 10:00 PM   #7
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Re: build a second fuel tank so complete 69gal

Brilliant! The redundant filters and pumps are a great idea; the English isn't too bad either.....way better than my German....
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Old 05-08-2015, 10:48 PM   #8
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Re: build a second fuel tank so complete 69gal

That doesn't look TUV approved!
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Old 05-30-2015, 03:44 PM   #9
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Re: build a second fuel tank so complete 69gal

Quote:
Originally Posted by rallypanam
That doesn't look TUV approved!

It would take a relatively simple pressure test for TÜV with 0.3 bar for an approval. Doable but nobody cares in africa..
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