Extended Range Fuel Tank add-on: Pros and Cons

[kdgreene]

Opinions Requested for a proposed modification, pros and cons so that I can compare with my own thoughts.

Our Fuso Expedition vehicle is back in the US having returned from our 18-country travel through Mexico, Central and South America, New Zealand and Australia. We are doing a bit of updating and modifications for our continued travels around the world. We are looking to travel across Africa then Asia starting at the end of this year.

I want to increase our mileage range by installing a larger or a second fuel tank. A second tank is difficult as we have only one place to install it, which would be between the existing tank and the rear wheels. Also, we are limited in size so that only a round 24-gallon tank would fit. Problem is that there are no used ones available only costly new ones.

So that brings me to my quandary. I can replace our existing 33 gal tank with a 50 gal tank off on Isuzu. If I install the 50 gal, the dimensions will cause it to extend out about one or two inches past the outside of the rear tires. It will not hang any lower than the existing tank.

I’d like opinions as to pros and cons of having the tank extend out past the line of the tires. Having the larger tank will increase our range by 200 miles. So is it worth taking the slight risk of using a wider tank? By the way we already have a loop step that hangs down from the camper and is approx three inches past the tires, and we have never hit it.

I have found a couple of tanks that would work and would like to order one before the end of the month. Thanks for the input.

Don & Kim Greene
http://www.QuestConnect.org
http://www.AmericasOverland.net

 

[RAM5500 CAMPERTHING]

What kind of rig?

The 44 gallon Aux tank i added to my 80 series Land Cruiser was one of the most useful mods i ever did! ZERO cons, if ya ask me! :victory:

 

[Harald Hansen]

Could you possibly protect the tank with a guard or "tree slider" of some kind?

 

[Mobryan]

I'd go for the seperate tank long before I'd put a larger single tank in.

Many times I've limped home on one tank, either from a fuel delievery issue in the other tank, or because the first tank suffered irrepairable trail damage.



Matt

 

[egn]

I agree fully with Matt. If you are really going overland then in my opinion two separate tanks are a must.

Beside having a fallback in case of damage a further advantage is that you can use the full content better. With a very long tank the problem is that when you going uphill or downhill that the fuel is either in the back or front of the tank. If the fuel pipe is at the opposite side the fuel pump will only suck air even your tank contains still fuel.

Don't you have custom tank builders?

My additional fuel tanks (1 at the side and 2 build into the frame) are custom build. So all available space is used efficiently.

 

[kdgreene]

Thanks for all of the thoughts.

We've considered custom tanks but have been put off by their cost.

We do not have much space for a second tank, it could only be installed immediately behind the existing tank or possibly between the frame rails. I did find one tank for the rear of the truck between the rails, but found that when our camper body was installed, the builder had to modify the area when they installed our tow hitch. To install the tank in that location I would have to remove the tow hitch/hook. I'm not sure that I want to do that.

I understand the issues of trail damage on the main tank, but in our experience we have never damaged a main tank. On this truck, our 2004 Fuso FG, we have already traveled some 65K miles (105K km) and never had any damage. In my talks with other overlander vehicle owners, none have sustained damage to their tanks. Although I know that this is always a possiblity, I think it is slight enough to reduce its importance in making a decision.

My thinking is that if I only have limited space that I should install the largest possible tank that would fit in that space.

Don Greene
http://www.QuestConnect.org
http://www.AmericasOverland.net

 

[ntsqd]

Have you looked into or considered the cross linked HDPE fuel tanks used in boats? They come in a variety of capacities & shapes. Overton's has a decent selection, as does West Marine. I'll venture that there are more sources than just these two.

 

[kdgreene]

Interesting idea about the HDPE fuel tanks. I'll check it out. Thanks
Don

 

[HenryJ]

Have you looked into or considered the cross linked HDPE fuel tanks used in boats? They come in a variety of capacities & shapes. Overton's has a decent selection...

I have been running one , purchased from Overtons , in my tool box for years now.

Auxilary Fuel Tank

Rotomolded of high-density, cross-linked polyethylene UV resistant material. Heavier weight material than what is used in an automotive racing application.

Mine is set up for swapping to my boat to extend its range if needed.

 

[egn]

The additional tanks at my vehicle are all HDPE tanks with 12 mm walls. They can be easily build in any shape.

 

[kdgreene]

Great ideas. Thanks for the photos. Wish I had the opportunity to install the tanks before I installed the camper body as I would have had more options available.

I've found a good deal on a used 55 gal fuel tank that would fit in the same spot at my exisiting 33 gal, it is just a more efficent use of the space as the replacement tank is rectangular and will fit right up to the frame, unlike the stock round tank.

I'll look around to see if I can find the space for a second tank between the rails as well.

Cheers!

 

[dhackney]

Don,

Extended range is a very good idea.

I will go +1 on the 2nd tank opinion.

If there is any way to put another tank on, I think it is a very good idea. Especially for some parts of Africa.

Doug

 

[Overdrive]

One disadvantage of a two-tank setup is that the switching valve(s) can malfunction, sticking one way or the other so you only have use of one tank until repair. I had a Ford with factory dual tanks, which incorporated an electric valve. The malfunctioning valve system left me stranded once (luckily, less than a mile from home!) Probably a relatively easy field repair, but...on the other hand, I had a different truck with an aftermarket Aero tank, and they used a manual valve system. I liked that much better.

I don't think there's a huge advantage of a two-tank system as far as the notion of "if you have a problem with one tank, you can fall back on the other". Because if you have two separate tanks, you double your risk of damage. Yes, I guess there would be some rare instances of an advantage, but if both tanks are exposed under the vehicle, it would be hard to prove an advantage. However, if a secondary tank is in a more protected location, then great.

 

[kdgreene]

Extended range tank

Well I've gotten our new fuel tank. Its a big 56 gal unit that came off of a new Isuzu. Of course it doesn't line up with the holes on our Fuso's chassis so I'll be doing some modifications to it. I'll be taking photos of the process and will post my successes and failures as I go. I'm starting today by removing the old 33 gal tank. Wish me luck!

Don