Rear Tub / Rear Quarter Fuel Tank

**sclarke** · 12th August 2007, 08:02 PM

This project started months back, but after several thought, mind changes and beers i completed the Aux Fuel tank.

I originally was going to put a Sill tank in Grommet the Zebra, but i choose not to at the end as i wanted a tucked away tank that was not going to change anything except the panel work....

So i found a new Series tank that was sitting around in a old blokes workshop..... Fred Smith....

It was an aftermarket tank and i need to change it to suit me as it was designed to have the filler in the cab and the pipes ran thru the cab to the rear tub. I wanted it all in the rear tub so i started cutting.
I cut the old fillers off and then plated it up and started the mounting. The new filler was added later after i mounted it

This took me many hours as i wanted it neat and strong.

Its bolted to the support brakets that hold the floor assembly onto the rear outrigger. Pic is taken from the back wheel looking forwards.
I made a new rear outrigger that ties the rear quarter near the wheel arch to the chassis.

The filler was the hard part, I cut up an expensive perfectly good filler for this and i could have got a crap filler and destroyed it, but ohh well.
I had a reducer made at the local Exhaust joint, the reducer allowed me to take the original neck and fit a mazda B2000 Van filler hose to it. i had to cut the hose back to suit my aplication, but at least i found the right angle.

I cut the panel up to take the filler and the 1st drill hole was very upsetting, i hate cutting good panels...

I then made a template and cut the hole for the filler Assembly, Ohh the Filler is from a Series Landy.

Then i fitted the Filler trim

Then i fitted the modified filler and the Tank (note the dint in the rear quarter on the left of the filler, Tree Hugging when i was out last weekend)

Then the hose, this was a Bitch to get on as the filler is mounted on the inside and the tank's pipe is up about 40mm thru the Tub floor.

Then i mounted the Transfer pump, this is a Elec pump i got from a Mazda 808, i'll run a filter before the pump and after the pump, i had some metal filings in the tank i could not get out, so these will filter them if the pick up pipe grabs it. I'm hoping the Facet pumps can lift Fuel.... if not i'm in the Sheeet.

I'm going to make a T-piece that will go into the normal filler breather. This is where i will pump the Aux fuel into the main tank.

The Aux Tank holds about 40-50 litres, so i'll only transfer the fuel when my main is down to about 1/4 and i'll keep an eye on the gauge when i do it.
How do i know when the Aux is empty???? the Facet pumps change noise when they are dry.

I'll post more pix when i connect it all up Tues.

Clarkie

**paulthepilot_5** · 13th August 2007, 01:45 PM

Ha Ha, Make sure you keep an eye on that fuel gauge when transfering the fuel

I have a similar set up for fuel transfer from my second tank in Yellow Pezza. I turned on the transfer pump one morning to top up the main tank, then walked away and forgot about it

needless to say the was a lot of diesel on the garage floor when i got back.

**awabbit6** · 13th August 2007, 03:49 PM

Originally Posted by sclarke

the Facet pumps change noise when they are dry.

Do they ever! They're a great little pump. Every spares kit should have one. You just can't kill them - as a main pump the noise will drive you insane though.

Excellent job!

I enjoy reading your mod posts!

**sclarke** · 14th August 2007, 08:16 AM

Originally Posted by awabbit6

Do they ever! They're a great little pump. Every spares kit should have one. You just can't kill them - as a main pump the noise will drive you insane though.

Excellent job!

I enjoy reading your mod posts!

As its only a transfer pump i will only have it on when i need to transfer from the Aux tank to the main.

But yes... if i dont keen an eye on the gauge i will be in the berries...

mmmm i should make a switch, so when the fuel sender is at the near full position the switch cuts the fuel pump out.
Mmmmmmmm all i need is to have a circuit, so when the fuel sender reads "X" resistance it cuts a relay out.
Will need to do some more research in this

**loanrangie** · 14th August 2007, 11:55 AM

Originally Posted by sclarke

As its only a transfer pump i will only have it on when i need to transfer from the Aux tank to the main.

But yes... if i dont keen an eye on the gauge i will be in the berries...

mmmm i should make a switch, so when the fuel sender is at the near full position the switch cuts the fuel pump out.
Mmmmmmmm all i need is to have a circuit, so when the fuel sender reads "X" resistance it cuts a relay out.
Will need to do some more research in this

What about some kind of timer relay ? Jaycar sell timer kits for all sorts of applications. Nice job, should give the Zebra a good touring range now.

**waynep** · 14th August 2007, 12:37 PM

Originally Posted by sclarke

mmmm i should make a switch, so when the fuel sender is at the near full position the switch cuts the fuel pump out.
Mmmmmmmm all i need is to have a circuit, so when the fuel sender reads "X" resistance it cuts a relay out.
Will need to do some more research in this

I was going to suggest that, or more simply you could install a float switch in the main tank that simply cuts out the pump when certain level is reached. I am pretty sure there are float switches available that wil lbe OK in diesel maybe look here :

www.rsaustralia.com

http://www.rsaustralia.com/cgi-bin/bv/rswww/searchBrowseAction.do?D=float%20switch&Nr=AND%28av l%3aau%2csearchDiscon_au%3aN%29&Ntk=I18NAll&Nty=1& Ntt=float%20switch&Dx=mode%20matchpartial&Ntx=mode %20matchpartial&N=0&No=25&name=SiteStandard&obs=sO bs&callingPage=/jsp/search/search.jsp&BV_.

With a bit of thought you could even put another float switches in bottom of the aux tank that cuts the pump out when it gets near empty.
..and another in the bottom of the main tank to auto START the pump when it gets low with a switch in the cab for auto /manual fill ( ohhhhhh....now my head is starting to hurt )

( float switch would need to have N/C and N/O contacts or use a relay )

..the tank looks good BTW ..I wish I had the abilities to do that sort of thing ...

**sclarke** · 15th August 2007, 06:29 PM

Its in, tested and filled.... Works a Treat.....

I'll sort the full cut off switch soon... just need to work out a way to do it cheap......

**bushrover** · 16th August 2007, 08:12 AM

With a bit of thought you could even put another float switches in bottom of the aux tank that cuts the pump out when it gets near empty.
..and another in the bottom of the main tank to auto START the pump when it gets low with a switch in the cab for auto /manual fill ( ohhhhhh....now my head is starting to hurt )

( float switch would need to have N/C and N/O contacts or use a relay )

..the tank looks good BTW ..I wish I had the abilities to do that sort of thing ...

[/QUOTE]

I hooked mine up to the low level warning light circuit. I fitted a rover fuel gauge into the aux tank. Pump comes on when the main tank is near empty and off when the aux tank is near empty. Used a couple of change over relays on the low level lights but its too early in the morning for me to remember how I hooked it up. Only problem is in rough country the pump switches on and off. If I work out how I did it and how to post an attachment I'll draw up a schematic and post.

**sclarke** · 16th August 2007, 05:57 PM

I was thinking of getting a kit from DSE that is the low level fuel alarm, then tweaking it so it cuts the aux tank out on high fuel. So the kit will be a High fuel alarm kit.

mcrover · 17th August 2007, 04:41 PM

Why not just have a hose running off the filler neck vent and back to the aux tank as well as Im assuming the fuel will take the path of least resistance so as long as the hose is big enough then it will get just above the hole and then bypass back to tank.

This wont tell you when it's full but you have a fuel guage for that but it does mean that you cantt over fill the tank.

Or even better, give it its own hole in the filler neck close to the tank so your not filling the whole neck before it bypasses.

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