Aux-Fuel cells

[JimWilliamson]

I added the Jaz 5gal Drag Race Horizontal (with foam), from Jegs.com for a few months.



Standard bike capacity about 4.75 gal. I had to fab the mounting frame. I didn't use the included AN fittings as plumbing for them was too costly. I went the route ultralight fuel tanks often use - rubber push-in bushings with automotive flexible black fuel line. The grommets seem flimsy but they're amazing and never leak.



Since the fuel cell is higher than the fuel system I used valves to separate it from the main tank. I put two valves onto the aux tank so I could control a reserve amount. The main/top/back valve I could reach around and open when moving. The valve on the bottom I had to stop and walk around to open. A few more photos of the setup on this crazy long, post-trip gear write-up page:
http://www.jimwilliamson.net/motorcycle/2005-09-us-n-canada/gear/

Ready to order parts?

5 Gal fuel cell
http://www.jegs.com/i/JAZ/547/250-005-01/10002/-1

Rubber bushing (drill hole in plastic tank the size of the bushing - push in bushing - push in fuel valve, etc - done)
http://www.aircraftspruce.com/catalog/appages/ftb01.php

Fuel valve
http://www.aircraftspruce.com/catalog/appages/ffv2.php

Fuel elbow
http://www.aircraftspruce.com/catalog/appages/ffelbow.php

Weight - only an issue when needing to pick up a sideways bike    I never noticed it when moving.

[yotes65]

Wow... Tony, thanks for starting this thread... I had plan on going with a TourTank & have it painted to match my bike... I think I will now go with a Jaz Tank w/ one of the covers made by Linda T... never thought about mounting in over the Pillion Seat... now to come up with a Mounting Bracket Design...

Thanks Again!

[Tony T]

Wow... Tony, thanks for starting this thread... I had plan on going with a TourTank & have it painted to match my bike... I think I will now go with a Jaz Tank w/ one of the covers made by Linda T... never thought about mounting in over the Pillion Seat... now to come up with a Mounting Bracket Design...

Thanks Again!

I thought about the Tourtank also, they look great but they are too frigging expensive. I found another tourtank type setup years ago that came with all the plumbing, (Forgot who made it.) but the plumbing was all plastic IIRC.

This is not something I want to cut corners on. So far I bought a 4ga Jaz tank, found one of my old unused filters, grounding wire, bought a cheap spare primary tank off ebay, and made a bottom bracket for the aux tank. Eventually I'll figure out a way to mount it to the frame without hacking away at the bodywork. That's really my stumbling block now.  

Nice setup Jim,   No leaks eh?

[patl]

Is there an advantage/disadvantage between the two 5-gal cells that Summit Racing sells:

http://www.summitracing.com/parts/SUM-290101/ (plastic, from Summit)
and
http://www.summitracing.com/parts/JZP-210-505-03/ (aluminum, by Jaz)
?

I'm looking for a 5-gallon cell for gravity fed application (not fuel pump).

[Tony T]

Is there an advantage/disadvantage between the two 5-gal cells that Summit Racing sells:

http://www.summitracing.com/parts/SUM-290101/ (plastic, from Summit)
and
http://www.summitracing.com/parts/JZP-210-505-03/ (aluminum, by Jaz)
?

I'm looking for a 5-gallon cell for gravity fed application (not fuel pump).

As far as I can tell there is no difference between the plastic Jegs, Jaz, and Summit fell cells besides price.

Both of the ones you have hot-linked should work just fine for a gravity fed system, (as long as the Aux tank is mounted higher than the main tank.) at least they are the ones everyone seems to be using.

[Slonishku]

I'm signing up for a pair of welding classes at my local JC this spring. I'm hoping to gain some aluminum welding skill to allow me to create various bike add-ons myself. I don't have anything specific in mind just yet, but Dean Tanji's FJR cells are my inspiration. Rugged, practical, and very good looking.

[scramblerracer123]

I bought a spare stock tank for the VFR and over the winter am going to experiment with enlarging it.  I would really like to get to the 300 mile range with the bike, so I only need to add 2.5 gallons.  Anyone tried this route with a vfr, or similar shaped tank?  

[CLAY]

I did it with my Bandit.  See page 2.  It's still working flawlessly.  I'd like to add a 4 gal aux tank to get to the 11.5 (I'd be at 11.2) gallons just to see how it goes.

[scramblerracer123]

I gave up on trying to enlarge a stock tank and mounted a 4gal plastic jegs fuel cell.  Might be a dumb question, but do I need to ground the fill ring on my plastic cell?  

[David Morrow]

A ground would never hurt. I recall from back in my boating days that you should always keep the filler handle from the pump in contact with the tank ( assuming an outboard motor & ungrounded tank) to avoid sparks from static. I'm no electrical genius, but I would go with the ounce (28.47 grams here in Canada) of prevention. On the other hand, I bet there are a lot of plastic aux tanks out there which are not grounded. Pick your poison.

[scramblerracer123]

David, was it you that had the great write up on mounting a fuel cell on a VFR.  If so, thanks, I looked over that write up many times.  

[David Morrow]

David, was it you that had the great write up on mounting a fuel cell on a VFR.  If so, thanks, I looked over that write up many times.  

This one ?
http://www.ldrider.ca/vfr-stuff/vfr-aux-tank/vfr-aux-tank.htm

That would be me.

I'm happy that it was of value to someone out there. Glad to help.

[D-Mac]

Fantastic write-up!

I'm doing mine pretty much the same way (except I decided to have a bung welded to the bottom of the tank - although I'm certain a bulkhead fitting would have been fine too).

Good tip about getting the right pipe tape. I hadn't realized that there was different types. I think you just explained why the white tape on the petcock of my 1970 Honda "melted" last year and then proceeded to clog up the carbs I had just cleaned  

[David Morrow]

Good tip about getting the right pipe tape. I hadn't realized that there was different types. I think you just explained why the white tape on the petcock of my 1970 Honda "melted" last year and then proceeded to clog up the carbs I had just cleaned  

I have a little sign in my kitchen that hung in our kitchen when I was growing up. It says :

" We get too soon old and too late smart "

[scramblerracer123]

Anyone have any suggestions on getting the plastic aviation style fuel cell filler cap to loosen.  If I didn't think the plastic turn part would break off I think I could lift the rear of the bike trying to pull this thing out each time.  I am considering using the dremel to open up the inside ring some, but am afraid it will then leak.  Anyone had any trouble with this?

[David Morrow]

Anyone have any suggestions on getting the plastic aviation style fuel cell filler cap to loosen.  If I didn't think the plastic turn part would break off I think I could lift the rear of the bike trying to pull this thing out each time.  I am considering using the dremel to open up the inside ring some, but am afraid it will then leak.  Anyone had any trouble with this?

I've seen a couple different styles of those fillers; can you attach a pic ?

[scramblerracer123]

Here are some pics of the cheap plastic fuel cell filler that is giving me trouble.

[David Morrow]

I have one similar to that but it's still in the shop drawer. I think I found an alternate solution because it was to fiddly.

I'm not sure how much trouble you want to go through to avoid future problems, but here's an idea if you want to go a slightly different route.

1) Make up an aluminum plate with the same outside diameter as the fitting that you have on your tank now.
2) Drill the six holes to match your existing fitting to bolt to your tank.
3) Cut a center hole to fit a screw on fuel cap bung
4) Weld the bung onto the plate
5) You now have a screw on filler cap

If you're really stuck, I can make the plate (no charge); you'd just have to buy the bung & cap and have it welded on. I have the lathe & other tools to do it right. I also have a spare bung so I can cut the inside hole for a perfect fit.

You can see the cap & bung on my tank here - very good quality.

http://www.ldrider.ca/fjrtech/fuelcellver2/fuelcellver2.htm

At Mark Williams the part numbers are Cap. - 5030 and Bung - 5020 and the pair cost about $45. There are other vendors out there.

[Tony T]

What about adding something like this? http://www.jegs.com/p/JAZ-Products/JAZ-Fast-Fill-Fuel-Cell-Components/746856/10002/-1

Might not be roll-over safe though.

[David Morrow]

I saw one like that on the Dean Tanji aux tank for the FJR. It would not be my first choice when you could get one that lays flatter to the tank. I hadn't thought about roll over issues but it's a good point.