Homemade Auxiliary Fuel Tank

the_wolf · Feb 12, 2013

I know its probably been done to death but i couldnt see any ideas that would do me.

Ive got fed up with my 90s tiny 45 litre tank and wanna get something to add a bit more. I cant weld whatsoever and wanna keep costs down so getting someone to make something up isnt really an option; same with buying one of those expensive off the shelf jobbys.

The idea that i had just now was to utilise a 25 litre plastic drum which i have in work. If i was able to mount this in the wheel arch would it be possible to use a switch operated in tank electric pump and connect it via a fuel line to my existing under seat tank so that at the press of a button i can refill half of my main tank when it starts to run empty? It sounds simple but would it work.

baggyjim · Feb 12, 2013

the_wolf said:
I know its probably been done to death but i couldnt see any ideas that would do me.

Ive got fed up with my 90s tiny 45 litre tank and wanna get something to add a bit more. I cant weld whatsoever and wanna keep costs down so getting someone to make something up isnt really an option; same with buying one of those expensive off the shelf jobbys.

The idea that i had just now was to utilise a 25 litre plastic drum which i have in work. If i was able to mount this in the wheel arch would it be possible to use a switch operated in tank electric pump and connect it via a fuel line to my existing under seat tank so that at the press of a button i can refill half of my main tank when it starts to run empty? It sounds simple but would it work.

why not just carry a jerry can. simples

the_wolf · Feb 12, 2013

I do, ive got two. But its just a pain having to remember to pull them out, fill em up and then to get out and fill the tank up again whereas with an aux tank i can just do it on the move.

disco147 · Feb 12, 2013

Excuse me for potentially being stupid/stating the obvious....but you want to carry fuel, in a plastic container, in yer wheel arch??

dogsbody · Feb 12, 2013

the_wolf said:
I know its probably been done to death but i couldnt see any ideas that would do me.

Ive got fed up with my 90s tiny 45 litre tank and wanna get something to add a bit more. I cant weld whatsoever and wanna keep costs down so getting someone to make something up isnt really an option; same with buying one of those expensive off the shelf jobbys.

The idea that i had just now was to utilise a 25 litre plastic drum which i have in work. If i was able to mount this in the wheel arch would it be possible to use a switch operated in tank electric pump and connect it via a fuel line to my existing under seat tank so that at the press of a button i can refill half of my main tank when it starts to run empty? It sounds simple but would it work.

This might be 'interesting' in the event of an accident.
The police would be interested
VOSA would be interested
Your insurers would be interested

Me? I'd be too busy running.

Lakes Rob · Feb 12, 2013

dogsbody said:
This might be 'interesting' in the event of an accident.
The police would be interested
VOSA would be interested
Your insurers would be interested

Me? I'd be too busy running.

+1:bolt:

the_wolf · Feb 12, 2013

arent modern fuel tanks made of plastic? Plus id have a metal guard bolted around it. Anyway thats why i asked the question, to see what others with more knowledge thought and possible solutions

dogsbody · Feb 12, 2013

Yes a lot of modern tanks are plastic but they're correctly designed and placed in vehicles to protect them. They're not just any old plastic drum (that you don't even know is not going to slowly dissolve from the inside) screwed in where there happens to be a space.
As for building some protection around it, unless you're going to conduct some crash tests how do you know that the metal won't twist at impact and puncture the tank?
I'm sorry but I can't think of a single good point in this plan. Even when empty your extra tank, full of fuel vapour, would still be a bomb looking for a detonator.

DEFENDER90-DAZ · Feb 12, 2013

Do a quick google for "overland" fuel tanks and you will find suppliers that can sell you a very nicely made aux fuel tank to fit to your 90 - if thats a bit too hard on the pocket stick to jerry cans

the_wolf · Feb 13, 2013

Fair do's, so its either jerry cans or a proper overland tank then

cheers very much, just always trying to think of a simple cheap solution

Jongould · Feb 13, 2013

If yours isn't a TD5 why not just get a TD5 fuel tank? You should be able to find a cheap second hand one, it will have a larger capacity and will be safer.

Agree with above about using a drum, its doubtful it would disolve but its not designed for durability and after a few knocks it will likely split...

the_wolf · Feb 13, 2013

Jongould said:
If yours isn't a TD5 why not just get a TD5 fuel tank? You should be able to find a cheap second hand one, it will have a larger capacity and will be safer.

Agree with above about using a drum, its doubtful it would disolve but its not designed for durability and after a few knocks it will likely split...

I could do. How could i go about mounting it up though? Im sure i read somewhere about others doing this and using a tank guard as the cradle but not confident on how sturdy that would be.

Also what would be the best way to plumb it in? This is all new to me so i gotta learn somewhere lol

diver · Feb 13, 2013

If you want a portable fuel tank that why not try one for an outboard motor. Don't know how you would mount it safely but they come with a variety of self sealing couplings. Usually available up to 30 litres.

Jongould · Feb 13, 2013

the_wolf said:
I could do. How could i go about mounting it up though? Im sure i read somewhere about others doing this and using a tank guard as the cradle but not confident on how sturdy that would be.

Also what would be the best way to plumb it in? This is all new to me so i gotta learn somewhere lol

I haven't done the conversion myself but I would expect the TD5 tank guard will be more than up to the job, you may need to drill a few holes for mounting but nothing that major. As for plumbing in, you can either go for a mechanical inline switch which you would lift the seat base to flick or an electrical one which you can control by a switch on the dash, the other option is a simple T piece but if one tank runs out before the other you will be sucking air in. Have a google search as its a common conversion to do...

trax · Feb 13, 2013

dogsbody said:
Yes a lot of modern tanks are plastic but they're correctly designed and placed in vehicles to protect them. They're not just any old plastic drum (that you don't even know is not going to slowly dissolve from the inside) screwed in where there happens to be a space.
As for building some protection around it, unless you're going to conduct some crash tests how do you know that the metal won't twist at impact and puncture the tank?
I'm sorry but I can't think of a single good point in this plan. Even when empty your extra tank, full of fuel vapour, would still be a bomb looking for a detonator.

You've watched too many movies. I'd still get a proper tank, but the risk of explosion is not great. Also diesel is a LOT harder to ignite than petrol.

the_wolf · Feb 13, 2013

I did see a very good one using a 50 litre plastic fuel tank that was sat up against the bulkhead in the back. The tank costs about 110 quid and looks very easy to hook up, even for someone like me with limited skills. Ive got the write up saved to my favourites so will stick the link up when i can

Edited to add: www.overland-rovers.com/alans-pages/vehicle-modifications/388-overlanding-in-a-defender-90.html

landowner · Feb 13, 2013

I would use a solenoid switch from an LPG set up to control the fuel, I did it with my LPG when I had two tanks, one LPG tank and one fork lift truck bottle in the back (no I didn't die)
Just switch it on and off from the dash and the pipes should be about the same size.
I recon a sturdy plastic drum for diesel would be as safe as a rusty thin metal tank and under the wheel arch is a good idea, if hit from the side the drum would flex and give rather than burst, I was thinking of putting my gas bottle there in the 110 but it was an inch too wide

the_wolf · Feb 13, 2013

Well thats what the drum used to contain funnily enough

so doubt it would melt. I reckon im gonna see if i can pinch the idea from the link ive posted and just connect it up via a 3 way 12v solenoid thingymabob. Switch in the dash will control the solenoid and would easily let me change it on the move. So far for the tank and valve itll be about 150 quid so still less than half the price for an off the shelf one and it should give me a fuel capacity of almost 100 litres. Not bad if it works lol

trax · Feb 13, 2013

Read what you said, but I think I'd just carry jerry cans tbh. If storage is a pita, then you could add a compartment where you plan to mount the aux tank. Would also be pretty useful for other gear.

Filling it up isn't that bad surely?

Jongould · Feb 13, 2013

I would seriously look at using a td5 tank, it's a much better option and it's cost won't be much more plus will add value to your fender, you can use the same solonoid setup, it's just the price of a second hand tank!

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