I didn't like the range of my 22 gallon gas tank. I had a spare '98 Caravan gas tank and fuel pump. I was going to use that but it's only 20 gallons, flat and wide. So instead I got a 26 gallon one out of a '99 Dodge Ram that's taller and takes up less bed space. I really wanted a 35 gallon out of a Ram but that was way too long and wouldn't work.





The metal I used for the fuel filler neck support. Look familiar?


This is a transfer tank only. It pumps out of the auxiliary tank into the main tank. I tapped into the factory fuel filler neck vent hose. I also spliced the vent from the rollover valve into the factory line so the vapors get collected into the charcoal canister instead of the bed of the truck. I used brass for durability. I don't trust plastic.



I installed a toggle switch to switch between the fuel level in the auxiliary tank and the main tank. I also installed a clear fuel filter to watch fuel flow so I'll know the tank is truly empty.

Main before pumping:


Auxiliary before pumping:


Main after pumping:


Auxiliary after pumping:


I had an normal lighted toggle switch to turn the fuel pump on. Well on my last trip I accidentally hit it. So I changed to an F-15 missile launcher type switch.

I’ll know this one is on.


I got some fuel tank straps from a Dodge van. They were longer so I had more room to customize them.

Bottom one is original length.


I folded it over like the factory for durability.


A.J.

 

That is a cool install. I'll throw it in the FAQ2 in the DIY section.
Maybe build a quick sheet metal box to cover it up so when hauling stuff in the bed it doesn't have a chance to possibly puncture it.

 

you didnt like the range of a 22; I had a 15 in my 94 reg cab and its range really sucked. I changed to a 22. I wish I could add the 15 back in as an aux. tank but at the same time both my trucks are shortbeds (one is a CC) and I dont wanna lose that much bed space to do so.

 

I plan on some type of protection for it. I threw this together as fast as I could for a recent trip to California. With this tank I only had to buy about 10 gallons in CA instead of 36 gallons. I'm going to paint the exposed metal and make it look better when I have extra time.

I get about 230 miles to a 22 gallon tank combo of city and highway (mostly city). I'm heavy on the throttle.

I didn't want to lose bed space either but there is no room under the bed unless you're really creative in relocating the exhaust. I don't use the max capacity of my bed so I'm not losing a whole lot. And at some point I'm going to make the auxiliary tank removable just in case. I still don't know how the race track is going to react to it.

A.J.

 

I took some more detailed pictures and also made a few modifications/improvements.

Here's the top of my auxiliary fuel tank sending unit. I used an old sending unit from my '94 Dakota with a few modifications. First the output/fuel filter was removed for the '92-'93 output/return fitting. Then the return was capped with a cap from another sender I got. My thinking is if I'm on the road and my fuel pump goes out, I can swap in the aux fuel pump to get home once I cut a hole in my bed for fuel pump access. The fuel filler vent was plugged with an extra electrical plug I had. I pulled the wires out and installed it in the rubber grommet where the fuel filler port lived. I did that because the tank came with the fuel filler vent. Then the rollover valve was replaced with a black cap that I got off of a Ram van fuel sender since the tank came with a roll over valve/vent.


I put the clear fuel filter up higher so I can see it in the rear view mirror. I have the two tanks on a toggle switch to see the level in both but we all know that empty isn't always empty. So now I can see the air bubbles when the pump starts sucking air.


I opened up an already existing hole to run the fuel, vent, and electric.


I painted the fuel filler neck and filler tube since the manufacturer never intended anyone to see them.








A.J.

 

I like it.
Fantastic job.

 

for real, very nice