TD5 Defender sill tanks

[Bundalene]

The following is a brief outline of the installation of a pair of sill tanks into a Defender, using the original fill point for both tanks. There is a pump on each tank to transfer diesel to the main tank. Total fuel capacity is now 187 litres (assuming 70l for the main tank) giving a comfortable range of in excess of 1200kms towing our boat. We have used these for quite a few kms and all works well.


I purchased the right tank on Ebay - I believe it is out of a TDi Defender. I had to relocate the fill point about 20mm lower to clear the TD5 chassis outrigger. Also replaced the breathers, fuel gauge and outlet. Finally the tank was coated internally with POR15 tank sealer. This tank holds 65 litres usable.

Right tank
http://img15.imageshack.us/img15/1076/mods1006.jpg (http://img15.imageshack.us/my.php?image=mods1006.jpg)

The left tank was manufactured using the right tank as a template (thanks to Andrew) The top was adapted to clear the battery box. Finally the tank was coated internally with POR15 tank sealer. This tank holds 42 litres usable.

Left tank
http://img15.imageshack.us/img15/8933/mods009.jpg (http://img15.imageshack.us/my.php?image=mods009.jpg)

I replaced the original TD5 plastic fuel filler with an earlier metal fuel filler. This required the enlarging of the hole through the body as the filler is slightly larger. The filler was modified to accept another fill point for the front tanks, also 2 breather positions and 2 fuel points to transfer fuel from the sill tanks. On the left in the photo below, is a standard filler. On the right is the modified filler.

It is possible to fill the front tanks separately to the rear tanks - by inserting the fuel bowser nozzle into the forward facing pipe. All the breathing from the tank is outside this area

Fuel filler
http://img8.imageshack.us/img8/8100/mods1081.jpg (http://img8.imageshack.us/my.php?image=mods1081.jpg)

This flexible line was used in a number of places - it was quite difficult and expensive to source.

50mm flexible fuel line
https://www.aulro.com/afvb/ (http://img15.imageshack.us/my.php?image=mods1082.jpg)

The fuel filler after connecting - all good quality fuel grade lines. Breather 1/2 inch, pressure 8mm and fill 50mm

Connected fuel filler
https://www.aulro.com/afvb/ (http://img27.imageshack.us/my.php?image=mods1089.jpg)

The left tank is accessed through a pipe just above the chassis with a home made TEE piece. All rigid pipe is exhaust pipe, mig welded as required. There are 2 breather points at the high point of each tank. A breather from each tank is run all the way back to the fill point.

TEE piece across the car
http://img27.imageshack.us/img27/9296/mods1090.jpg (http://img27.imageshack.us/my.php?image=mods1090.jpg)

The outlets are facing forward tucked up above and protected by the chassis out riggers. These were kept as low as possible to maximise the available fuel in the tank

Tank fuel outlet prior to pump
http://img27.imageshack.us/img27/8743/mar30008.jpg (http://img27.imageshack.us/my.php?image=mar30008.jpg)

The fuel pumps are probably the wrong type for the application but they work well. They are actually pressure pumps. I have connected the suction line with 12mm (1/2 inch) line and the outlet with 8mm line

Fuel pump
http://img27.imageshack.us/img27/8813/mar30010q.jpg (http://img27.imageshack.us/my.php?image=mar30010q.jpg)

Fuel transfer is done from the dash by the 2 switches at the upper left of the dash. The left switch transfers fuel from the left tank and the right from the right tank. A have yet to install a digital readout for the 2 tanks . This will be located immediately under the radio. I am currently working on the fuel gauge display. It takes about 30 minutes to empty each front tank.

Dash switches
https://www.aulro.com/afvb/ (http://img8.imageshack.us/my.php?image=mar30042.jpg)

[Bundalene]

The end result with the tanks tucked above the limits of the chassis rails and out riggers. Please ask if anyone wants more info or photos.

http://img211.imageshack.us/img211/349/dsc0017173.jpg (http://img211.imageshack.us/my.php?image=dsc0017173.jpg)
(photo courtesy of Lou)

Erich

[mrapocalypse]

Very cool.

Ian.

[weeds]

i missed this thread...........good set up

[slug_burner]

good work

[isuzurover]

I missed this thread. Is Andrew planning to make any more??? Would be interested in a price.

[andrew e]

I missed this thread. Is Andrew planning to make any more??? Would be interested in a price.

Very big "no".

I suck at being a sheety. I didnt use a folder, and there are about 18 or 20 sides to the tank.

They took about 20hours to make each, and i still managed to put the pickup in the wrong spot.

I made some for my car, (and bought an extra one off another AULRO member), so i'll ask a local sheety what he would charge to copy it next time i get a chance. IIRC the retail of these tanks in the ARB catalouge is $1400, but thats for the drivers side only, they dont do one for the pas.

Andy

[dullbird]

and what a lovely photo it is erich....need any more just give me a shout:)

[geckos]

more pic pleeeeeeeeeeeeeeeeeeeeaaaaaaaaaaaaaaaassssssssssss eee!
cheers geck

[scott oz]

[/URL]

This flexible line was used in a number of places - it was quite difficult and expensive to source.

50mm flexible fuel line
http://img15.imageshack.us/img15/1312/mods1082.jpg (http://img8.imageshack.us/my.php?image=mods1081.jpg)

The fuel filler after connecting - all good quality fuel grade lines. Breather 1/2 inch, pressure 8mm and fill 50mm

Connected fuel filler
http://img27.imageshack.us/img27/7039/mods1089.jpg (http://img27.imageshack.us/my.php?image=mods1089.jpg)

The left tank is accessed through a pipe just above the chassis with a home made TEE piece. All rigid pipe is exhaust pipe, mig welded as required. There are 2 breather points at the high point of each tank. A breather from each tank is run all the way back to the fill point.
[URL="http://img8.imageshack.us/my.php?image=mar30042.jpg"]


Bundalene

Great post.

The flexible fuel line would you mind letting me know where you sourced it.

Also the two red hoses am I correct that these are the breathers in which case I’m curious as to where you plumbed in the lines from the belly tanks to the main

[bushrover]

Fuel transfer is done from the dash by the 2 switches at the upper left of the dash. The left switch transfers fuel from the left tank and the right from the right tank. A have yet to install a digital readout for the 2 tanks . This will be located immediately under the radio. I am currently working on the fuel gauge display. It takes about 30 minutes to empty each front tank.

Dash switches
http://img8.imageshack.us/img8/9770/mar30042.jpg (http://img8.imageshack.us/my.php?image=mar30042.jpg)

Great job. Can you tell me where you got the switches??

Rick

[Bundalene]

Bundalene

Great post.

The flexible fuel line would you mind letting me know where you sourced it.

Also the two red hoses am I correct that these are the breathers in which case I’m curious as to where you plumbed in the lines from the belly tanks to the main

Hi Scott.

I sourced the fuel line from a local company PR P Wallis, and I am pretty sure it is a 'GATES' product. At the time it was around $80 for a 90cm length. It is a fuel grade spiral wire hose - semi flexible. With our current $$$ exchange rates the prices should be less.

As for the red hoses, I ran a separate hose from each tank back to the top of the filler neck. There are 2 breathers at the top of each tank, joined by a 'Tee' connector. The 'Tee' fittings are screwed to the underside of the cabin floor - a point slightly higher than the tanks and then they basically followed the filler lines back. I ran the breather in 1/2 inch to allow high flow filling. The set-up works very well.

Erich

[nostromo]

thanks for solving the puzzle Bundalene, and for the pics to show us how we can create what we need for the 90.

[xrodney]

can someone tell me where I can find td5 dash switches without any signs on them? I want to use them as diff lock switches. FRONT, REAR and COMPRESSOR

[Chops]

An old thread I know, but I'm dredging though trying to find various info on extra fuel tanks etc.

Just wondering Erich, if there's anyway you could repost the pics? If you prefer, I can give you an email.

[vince_sally]

G'day folks, I missed this one. Should give me ideas for my D2 TD5
Any chance of getting the photos so as to see how to set up my 2 x 45lt+ recently acquired sill tanks, as don't wish to join the photo's link site, due to privacy reason. Thanks in advance

[d2dave]

No pics for me. This is what comes up on my screen. When I click on one all I get is ads for imageshack. Can anyone explain this?



https://www.aulro.com/afvb/images/imported/2014/12/534.jpg

[loanrangie]

Look at the date Dave, after 5 years they have probably moved or been deleted.

[d2dave]

Thanks. Didn't notice the dates. Just thought it was a new thread and every one was commenting how good it looks and all I could see was ads.

[Bundalene]

I still have the pics on file and will re post when time permits - a bit fiddly



Erich

[Bundalene]

This has been re posted with photos


http://www.aulro.com/afvb/showthread.php?p=2285268#post2285268


We have more info or pics if anyone wants them

Erich