jphilipson
Registered
Finished up part one of my aux fuel project - plumbing everything for the main tank and routing to the aft.
Tomorrow I will mount up the 5 gallon Aux cell (Tourtank) and connect to the system
This is a 100% gravity fed system. The aux tank is higher than the main - so wait till the main tank is almost empty, throw the valve, and gravity will back-feed the main tank. System is 5/16 fittings and fuel line.
Was originally planning on using a bulkhead fitting, but the tank openings are way to small to correctly install one. I could not even get a hand halfway in the opening, never mind get a wrench on the fitting inside. So rather than risk a bad connection, I decided to go the weld-on bung route.
Tank and rear plastics off - fuel line laid in place.
3 washes with soapy water, then letting the hose run through the tank to rinse it for half an hour did the trick. Killed almost all gas odors. After washing the tank multiple times , I dried the tank with a shop vac, then rags - Then let it bake in the Colorado sun for the rest of the day.
By late afternoon it was ready to get the bung welded in. Got referral from a friend on another forum, and the guy hooked me up. He runs a race team out of his shop, and is a much better welder than me
This is a 1/4 NPT threaded bung welded into the tank.
A little closer in. The rough spot was due to some contamination causing the weld to bubble out. After regrinding a bit the weld took better.
Got the tank back together, fuel pump assy back in, and elbow 5/16 barb into the tank. Threads sealed with TFE paste. The tank fitting also made a nice retainer for the tank's heat shields.
Tank re-installed showing the fitting on the bottom.
Rear of bike, under passenger seat showing the qucik disconnect fitting to make tank removal a breeze.
After all the plastics put back on.
After getting everything back together I put the ~1/2 Gallon of gas I had drained from the tank back in and headed down to the gas station to fill it up. I also added some crap to remove water from the fuel as a precaution after having washed the tank. The tank baked in the 90 degree sun all day after being dried with the shop vac/rags, so this was just a little added protection. After a quick ride with the tank full, I double checked everything, and no leaks anywhere. Finger tested everything and no stink finger.
That's it for part one. Everything is plumbed and ready to go for part two - getting the aux tank mounted on the back and hooked in. I pretty much have everything ready for that tomorrow (wood template drilled etc), so will be pretty quick. Just need to drill my mounting plate using the template, and attach to the existing rack.
Part two coming soon
Tomorrow I will mount up the 5 gallon Aux cell (Tourtank) and connect to the system
This is a 100% gravity fed system. The aux tank is higher than the main - so wait till the main tank is almost empty, throw the valve, and gravity will back-feed the main tank. System is 5/16 fittings and fuel line.
Was originally planning on using a bulkhead fitting, but the tank openings are way to small to correctly install one. I could not even get a hand halfway in the opening, never mind get a wrench on the fitting inside. So rather than risk a bad connection, I decided to go the weld-on bung route.
Tank and rear plastics off - fuel line laid in place.
3 washes with soapy water, then letting the hose run through the tank to rinse it for half an hour did the trick. Killed almost all gas odors. After washing the tank multiple times , I dried the tank with a shop vac, then rags - Then let it bake in the Colorado sun for the rest of the day.
By late afternoon it was ready to get the bung welded in. Got referral from a friend on another forum, and the guy hooked me up. He runs a race team out of his shop, and is a much better welder than me
This is a 1/4 NPT threaded bung welded into the tank.
A little closer in. The rough spot was due to some contamination causing the weld to bubble out. After regrinding a bit the weld took better.
Got the tank back together, fuel pump assy back in, and elbow 5/16 barb into the tank. Threads sealed with TFE paste. The tank fitting also made a nice retainer for the tank's heat shields.
Tank re-installed showing the fitting on the bottom.
Rear of bike, under passenger seat showing the qucik disconnect fitting to make tank removal a breeze.
After all the plastics put back on.
After getting everything back together I put the ~1/2 Gallon of gas I had drained from the tank back in and headed down to the gas station to fill it up. I also added some crap to remove water from the fuel as a precaution after having washed the tank. The tank baked in the 90 degree sun all day after being dried with the shop vac/rags, so this was just a little added protection. After a quick ride with the tank full, I double checked everything, and no leaks anywhere. Finger tested everything and no stink finger.
That's it for part one. Everything is plumbed and ready to go for part two - getting the aux tank mounted on the back and hooked in. I pretty much have everything ready for that tomorrow (wood template drilled etc), so will be pretty quick. Just need to drill my mounting plate using the template, and attach to the existing rack.
Part two coming soon