Aux-Fuel cells

[Tony T]

Mods please leave this in the IBA section, it is a IBA specific modification.  

We don't have a thread about fuel cells here. Warchild used to have a great blog about his fuel cell on the XX but it seems to be down when I do a search for his page.  

I'm looking to add a 4ga fuel cell to my bike this year and would like to tap into the wealth of knowledge of those that already have done so. Mainly I'm looking for the details of the hook-up and what parts you used. How to run the lines, a good way to tap into the tank, what valves to use, what valves to stay away from, pictures of brackets . . . . ect.

Basically any tips and advice you would have please post up and educate the uneducated.  

[whodat]

What kind of bike? The parts needed and the hookup can vary between bikes. I've got a 4 gallon Tourtank I use on my Tiger set up on a spare pillion seat and plumbed with quick connect fittings, all gravity fed. Takes me about a minute to put on or take off the aux tank.

[Tony T]

A Triumph Trophy. A gravity feed system is what I looking for. (Carbs)

Do you have some type of bracket / cradle for it or do you just strap it to the seat?  

[Lonerockz]

Yes more info please! This winter I plan to add a second fuel cell. I don't want to plumb into the fuel tank though so I was planing on cutting the fuel line putting in a Y then having a fuel pump in my Cell. Switches to turn off the fuel pumps. I was going to put check valves and quick disconnects inline between the pumps and the engine. Anyone see issues with this setup?

Any leads on where custom tanks can be made?

I found that Lab supply companies have really cheap and (near as I can tell) identical quick disconnects and check valves as some of the motorcycle/racing parts places.

I have an 08 Kawasaki Versys.

Steve

[Tony T]

Anyone see issues with this setup?

Steve

Yes, pumps can fail.  

For me I don't think splicing into the existing fuel lines would be good, there are 2 of them that feed the carbs and I want to be able to watch the fuel gauge on the dash. I would like to mount the aux tank to the rear oem rack but I'm worried about overloading it with 4ga of gas + tank weight.  

[Warchild]

I would like to mount the aux tank to the rear oem rack but I'm worried about overloading it with 4ga of gas + tank weight.  

Consider placing of the cell on the pillion seat area. Then the weight becomes almost a non-issue....



Let's say that your cell and mounting rack weighs 15 lbs. If we weigh gas at ~6.2 lbs per gallon, then even when fully fueled, your entire setup weighs less that 40lbs....  not much of an impact, if the weight resides on the pillion area. Then you can use your rear rack for something useful, like a 1-gallon water-jug, or a Ventura Bag.

Or both....

[Davo]

Links to mine.

My earlier bike a Kawasaki 1000GTR / Concours
http://www.davojones.com/auxtank.htm
3.5 gal Tourtank - pic done prior to fitting quick disconnect.


My current Kawasaki 1400GTR / Concours14
http://www.davojones.com/auxtankroo.htm

5 gal Jazz tank

[DNA]

Great thread.

I have a 5 gal plastic tank wiht all the fittings attached, but no hook up or connectors.  

It sits in the garage asking to be installed - I think I should just sell it for the $75 I paid (it was an extra from an east coast rally master who did not need it for the 2008 IBR),

If I post a pic of the tank on the floor - I can get it out of my garage and loose the guilt?

I am basically stuck on how to plumb it into my plastic gas tank.  I know there are various bulkhead fittings that can be used, but I have not looked that thoroughly and would dearly love someone to just set me up with a fitting and connector kit - or buy it from me so i can quit thinking about it.

[yamatech2003]

Keep em coming guys. This is something I have been interested in adding over the last couple of years. Definately something I would like to have in time for the Void rally this fall. I'm riding an 06 FJR and have a spare back seat to permenately mount it to. Is this a bad idea? Would it pass tech inspection? IIRC IBA rules state that the aux tanks bracket must bolt directly to the frame?

I think I am going to use a JAZ tank due to the price point and add a bulkhead fitting to my stock tank. Most likely going to gravity feed.

[DNA]

Damn you all - now I am looking at these fittings - thinking just how easy this could be...

http://www.jazproducts.com/AN_fittings.html#bulkheadnut

[Bill Lance]

Glad to see this thread.

As much as I want to add a fuel cell, there is no way I would tackle the project alone.

Does anyone here know of a shop or an individual who does this type of work.  I want it done correctly, and am not afraid to pay well for quality work. I live in western NC--the Southeast US would be preferred.  Thank you!!

Bill

[Davo]

I think I am going to use a JAZ tank due to the price point and add a bulkhead fitting to my stock tank. Most likely going to gravity feed.

Its morning in Australia and I am at work, at home I have links to fitting bulkhead fitting to your FJR tank and will post later unless someone does first.

It is very similar to mine on the Kawasaki.


Undo and remove your fuel pump which will give you room to get your hand inside, place a container in there to catch any filings from the drill and flush out WELL after.

[DNA]

Thanks DaveO - would you do this type of install on a plastic tank?  The only metal part is the fuel pump plate - I was thinking I could try to find a place to drill that - but the plastic sure would be easy - IF it was safe.

BTW - can you post up on the shut off valve you are using?  I had heard of one that was awesome - the "must use" piece - but I lost the link.

[Tony T]

Great write-up Davo, thanks for posting that.  

The rack on your 1400gtr looks fantastic, very nicely done. It gives me better ideas on how to make one that works well and doesn't look like crap. That is one of my stumbling blocks on how to do this mod, how to make a rack that works and also look halfway decent.

Like DNA I'm curious about the parts you used. Mainly the bulkhead fitting, quick-disconnect, and shutoff valve.

Anyone else have tips / pictures they like to share with the class?  

[Tony T]

Consider placing of the cell on the pillion seat area. Then the weight becomes almost a non-issue....

Excellent point Warchild, good to see you post here again.  

The only reason I lean towards mounting the tank on the oem rack is for ease of mounting it there. I really rather not cut into the seat or the flaring to get this done but am finding it difficult to find a "above the seat" solution without hacking away at things. In all reality the weight would just be too much for the oem rack and I would be risking the whole thing bouncing down the hwy.

Once I have the mounting rack figured out the rest should be easy.  

[Black Ice]

Excellent point Warchild, good to see you post here again.

I wish he'd quit being an International Man Of Mystery and hang out here more often.

But then, he's usually too busy doing crazy shit like riding his bike.  Who does that?  

[Davo]

Thanks DaveO - would you do this type of install on a plastic tank?  The only metal part is the fuel pump plate - I was thinking I could try to find a place to drill that - but the plastic sure would be easy - IF it was safe.

BTW - can you post up on the shut off valve you are using?  I had heard of one that was awesome - the "must use" piece - but I lost the link.

My bike is currently on the ocean on the way to Portland for my IBR ride so I can only go on file images I have.



More on the whole thing here on my GTR-AUS site.
http://gtr1000.yuku.com/topic/3121?page=1

[yamatech2003]

Thanks Davo, looks very good. Good luck in the IBR it's going to be a great rally this year!

[guitardad]

Good timing, guys!  Like Yamatech, I'm trying to work up a cell install for the Void this fall.  Now a question....  How high above the bottom of the main tank should the bottom of the aux cell really be in order to work as a gravity feed?  I'm trying to get the cell low enough to push it back against my topcase, but still allow the case to open without any interference.  And I'd much prefer gravity to a transfer pump.

[Davo]

I started working life as a plumber, same principal. As long as its higher it MUST flow from one to the other. Clearly higher creates a better head pressure but it is not that important with these. The worst would be you let the main tank completely empty and as long as the flow rate from the aux is faster than the fuel being used it will fill.

So don't let the main completely empty and if you do don't ride at 150mph