How To Add A Second Fuel Tank To Isuzu Box

1. 28th June 2012,07:41 PM #1

   Second fuel tank

   I want to put a second fuel tank out of a 2a nether pass seat of my sons 88". Any tips or problems i might see?

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2. 29th June 2012,x:59 PM #two

   You lot will need to accept a bracket fabricated to the forepart out rigger, to concur the front of the tank, I am having one made at present, once I go information technology I volition mail a motion-picture show for you

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3. 30th June 2012,12:44 AM #three

   Originally Posted by rangietragic

   I want to put a 2nd fuel tank out of a 2a nether pass seat of my sons 88". Any tips or issues i might come across?

   Been through this exercise just recently with my '76 Series 3 LWB. Got concur of a second hand filler neck, fuel cap and escutcheon, and a new (old stock) 45litre fuel tank. Bought a fuel gauge sender, a new rubber connection between the fuel filler neck and the fuel tank. Had a bracket manufactured to support the front of the tank (the rear attached to the chassis outrigger with existing holes). I made a pattern to guide the cutting of the hole for the second filler cervix (can lend you lot that if you wish). Hardest part was cutting the hole in the platform backside the seat box for the filler spout and breather tube on the tank to poke through. Getting this in the correct place was tricky. Also the safe connectedness betwixt the filler neck and the spout has to be modified to turn it into a left-mitt one because y'all can merely buy right-manus ones. This involves cutting the connector in the middle, inserting a piece of exhaust pipe, allowing yous to rotate the 2 ends of the connector into the right position to orient them to the filler cervix and the spout on the tank. This is like 1 of those executive puzzles- only one orientation is correct, and it merely requires patience to get information technology so it all lines up.
   My Serial III has a breather for pollution command, and I simply T-continued into this for the second tank.
   This thread:
   Series three Auxilliary Tank

   includes lots of advice and ideas from other friendly folk on this forum who helped me while I was installing mine, and there are a couple of photos of work in progress. I estimate you know that you'll have to remove the entire seat box to make the installation easy. Taking this out isn't hard, but a little tedious....
   I have some more photos that I didn't put up on this thread if you lot are interested.
   I rigged a modest switch and an LED on the dash which allows me to switch the fuel gauge between the main tank or the auxilliary tank. The LED comes on when the auxilliary tank is selected by the switch to remind me which one the guess is reading from.
   I installed the fuel alter-over tap on the little platform immediately behind the middle seat dorsum. This was the easiest place to route the fuel lines to, and it has the added advantage that when the seat back is upright y'all tin't see the tap. So, if you exit it turned off when the vehicle is unattended, anyone trying to steal it won't get far, and probably won't think to await for a fuel tap, let lone ane mounted correct behind the center seat.
   The only problem I've had then far was a little vapour lock when running on a hot 24-hour interval and so parking for lunch. I had to change back to the main tank to go moving, but equally presently as there was airflow again, I was able to go back to the auxilliary. It was probably just the fuel lines getting rut-soaked during the finish. I also installed a heat shield over the frazzle pipe which runs correct underneath the fuel tank.
   Hope that helps,
   Regards

   Coop

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4. 30th June 2012,04:36 PM #4

   I am near to do this also, with a 1977 swb, using twin 10 gallon tanks, and Bearmach fuel tank outriggers for both sides.

   Coop, would it exist possible for y'all to provide the location dimensions for the 2 holes that accept to be cutting in the rear of the seat box platform to accomodate the filler & breather pipes?
   As well, a photo of your tap/switching arrangement would be great also.

   Thanks
   Geoff

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5. 30th June 2012,04:38 PM #5

   Might also need to borrow your cut template

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6. 1st July 2012,01:29 AM #vi

   Originally Posted past 68wicksy

   I am about to do this also, with a 1977 swb, using twin 10 gallon tanks, and Bearmach fuel tank outriggers for both sides.

   Coop, would information technology be possible for you to provide the location dimensions for the two holes that have to be cut in the rear of the seat box platform to accommodate the filler & breather pipes?
   Besides, a photograph of your tap/switching arrangement would be great also.

   Cheers
   Geoff

   Ok, here'south the tap and fuel piping arrangements. I got the tap from a marine store. There'south a shot of the fuel inlet arrangements also.
   I'll practice my all-time with the dimensions of the template, but I have to admit I had bug sorting this and ended up with the holes having to be re-bundled several times until I got them correct. I ended up making some other plate to go over the filler spout and breather which covered the somewhat messy holes I'd created in the platform. I'll give yous the location and dimensions of that one time I've had a run a risk to measure them upward and have photos.
   I finished up with a elementary double-pole double throw switch on the dash to change over the judge. One throw switches the LED on or off, and the other throw switches the input to the fuel gauge from the right or left tank. Setting upwards switches on the fuel tap itself proved besides complex, so I didn't proceed with that idea.

   Fuel tap earlier installation
   IMG_5078.jpg
   Fuel tap installed. The hose running in a higher place the crank handle is the breather tube connectedness to the anti-pollution gear.
   IMG_5079.jpg
   Fuel tap and lines. The slice of copper pipage prevents the fuel hose chafing. The scarlet wire's from the fuel tank sender.
   IMG_5080.jpg
   Fuel tank inlet
   IMG_5074.jpg
   Alter Over Switch on dash (Aux selected, LED on)
   Fuel Gauge Change switch.jpg

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7. 1st July 2012,01:31 AM #7

   Originally Posted past 68wicksy

   Might also demand to borrow your cut template

   PM me an address and I'll post it to you lot. It's a piece of aluminium, so won't toll much. And so perhaps you tin can send information technology to whoever needs information technology adjacent.

   Coop

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8. 1st July 2012,05:09 PM #8

   Hi Coop

   Very grateful for the time and effort you have taken to give such an informative reply. This will make the job a lot easier for me when I tackle it. Have sent you a PM about the template.

   Cheers
   Geoff

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9. 1st July 2012,07:36 PM #9

   Originally Posted by 68wicksy

   Hi Coop

   Very grateful for the fourth dimension and effort y'all have taken to requite such an informative answer. This will make the task a lot easier for me when I tackle it. Have sent you a PM about the template.

   Cheers
   Geoff

   OK, here's what you lot will be getting in the post. I fabricated it by attaching a slice of aluminium to the new escutcheon so cut out the centre. If you measure from the edge of the door to the edge of your escutcheon on the driver's side, then measure from the edge of the door to the edge of the template on the passenger's side, then it should be in the right place to mark out the hole. I cut mine out with a jigsaw with a metallic cut bract and so filed the last flake to get a tight fit.
   I've too included some shots of the holes where the tank spout and breather come upwardly through that litle platform. Note that I have inserted a plate over the top of the platform considering the pigsty I concluded up with was larger than it needed to exist because I kept having to shift it. That plate is the same width as the shelf. I've included a shot with a ruler and so possibly you can take some measurements and become yours much closer to the correct spot in the commencement place. All this assumes, of course, that your tank dimensions are the aforementioned as mine- at least as far equally the location of the various inlets is concerned.

   Here's a couple shots of the template:
   Tankdetails2.jpg
   Tankdetails3.jpg

   And here's some shots of the inlet and breather, taken from straight above. I included a ruler in one and so perhaps you can take some rough measurements from it (the millimeters evidence if you lot enlarge the image.)
   Tankdetails1.jpg
   Tankdetails4.jpg

   All-time of luck,

   Coop

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How To Add A Second Fuel Tank To Isuzu Box,

Source: https://www.aulro.com/afvb/series-iii/153628-second-fuel-tank.html

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