Box mounted fuel tank and tool box

[Shadrach]

I have a canopy on my 03 3500 and I wanted an aux tank. After reading the article in issue 75 on page 59 I gave it some serious thought. I considered doing it the same way as the writer did and researched a single directional fuel pump ( I didn't see a need to "pump" it down hill ).



First I had to find a tank. I found a locally made 30 gal ( 115 litres ) one and was about to order it when a former co-worker showed up to show me his 05 short box CTD powered Dodge he had just bought. He had just removed the 75 gal ( 280 litres ) tank and said he didn't have a use for it. I bought it for 1/4 of the price of the new one. Since I have a long box I didn't mind loosing 15" of space. Now I needed a way to fill it.



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I found a nice pump that would pump 13 gpm ( 50 litres ), twice what his bi- directional one would. I figured there has to be an easier way. Then one day I saw a canopy on a company truck with a hinged door in the side instead of a window. AHA!!! I contacted the canopy store I deal with and ordered a "windoor" - a tinted glass door hinged on the top. I bought it and had it installed quicker and for less than the pump would have cost.



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It is real easy to fill. I put about 65 gal ( 250 litres ) in it so far. I installed a sending unit and a fuel gauge in the cab with an electric solenoid to control it and a lighted switch. I also have a ball valve on it as well.



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[Shadrach]

Now for the tool box. I had my brother build me a wooden one to my specs and size. I mounted it on top of the tank and put a piece of 1/4 plywood on the exposed side of the tank to protect the tank from dents, similar to the way it was done in the magazine article. We cut a 2x4 to length and notched it to fit under the bed rail, screwed the box to it and clamped it to the bed rails with canopy clamps. This prevents the box from siding off the metal fuel tank. I painted it flat black so if some undesirable looks thru my canopy windows they won't see it as easy. The inside has a sliding tray and is painted white to make it easier to see into. I had to change the fancy hinges he mounted on it as the lid hit the roof of the canopy.

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[S.Morris]

Looks good... ... . wish I could carry that much extra fuel at times.

 

[Shadrach]

Update: After doing a trip of over 800 kms ( 500 miles ) I discovered my electric solenoid wasn't opening. It would click but apparently it wasn't opening enough. Even though I had half a tank full in the box I still had to stop and buy some to get back home. When we got back I took it off and it was only allowing a dribble thru. I have left if off for now as I am headed off to the West coast next week. Because I have the windor in the canopy I can reach in and use the manual shut off. I do need to put a light in the canopy for night fill ups. Shad

 

[Shadrach]

double message oops

 

[Allnew2Me]

That solenoid may be directional, with an arrow cast into the bottom to show flow direction. You might want to check that first.

 

[AMinneman]

Shad... just got back on TDR and saw your post about the fuel solenoid. I installed an RDS 60Gal/Tool box combo on my 07. 5 and put 2 solenoids - 1 for the fuel and the other for a vent line. I installed it as you did the first time and discovered it doesn't flow very well without venting it at the same time. The aux tank feeds into the filler neck hose and since it sits above the OEM tank I don't have a pump and let gravity do the job. Takes about 45 minutes to transfer 30 gals to the main tank.

 

[BIGNASTY]

Shad



Your tank looks about like my Aero fuel tank mine is 65 gal. I wouldn't be without it on long trips ITS A MONEY SAVER you can pick and choose where and when you buy fuel. When moving to MT I would fill up in NV and drive back into CA and load the trailer then go back into NV where the fuel was cheaper and refuel and not think about fuel again until I got to MT. Mine has a carter fuel pump to transfer the fuel to the TRUCK TANK. I make the transfer when the truck tank gets to 1/4 and have it on a 12 volt timer so if I forget I have it on it shuts of automatically. The system worked fine except for the fuel would continue to siphon from the AUX tank to the truck tank so I never REALLY knew how much was left in the AUX tank. It has a gauge but didn't seem quite accurate so I made a post here on TDR and found that a fuel tank switch from a Chevy saddle tank would fire the same time as I started the timer it opens the fuel line and when the timer shut off the switch would close and stop the siphon. It sounds trivial but I kind of like to KNOW how much fuel I REALLY have. Also on mine I have a T that was put into the fuel fill for the truck tank that way if the truck tank got full and the pump was still on the fuel would just flow from tank to tank.



BIG



After posting I read AMinneman's post about letting gravity do the job. That was one of my thoughts also but in talking to some of the mech's at work they said that would not be legal (I know who Care's) I DO. the reason the DOT gave me was because if the truck rolled and landed wrong that the fuel would siphon out there is supposed to be a switched valve in line to prevent that along with a ONE WAY vent that mine had from Aero tank. Just a thought have a good trip. AND JUST REMEMBER THAT IT HAS TO BE FILLED SOMETIME and thats where it looks like BIG BUCKS most gas stations look at you kind of weird when you pull in , in a pickup and get 90gal of fuel

 

[Shadrach]

I had the arrow going the right direction. The solenoid went clunk but it just wasn't opening, faulty one. I had both filler caps off when I was trying to drain the fuel to the main tank and after 30 min with the key on while sitting in the campground the dash needle barely moved. I will try the manual valve only on the trip. I think I will also put a vent from the right hand side of the tank to the filler neck as I normally part with the left side lower. That will have to wait til I get back. Shad

 

[AMinneman]

shad... the aux tank gauge is cool but i figured once the tank is empty (by watching the oem guage) i should have at least a tank or close to it to find a fueling place. The timer is my next upgrade as i have left the switch open, overlooked it and the solenoid stays activated til i wake up or the solenoid goes kaput (already replaced it once). the only saving grace in my system is once the fuel in the filler neck reaches the level of the input hose then it cant keep draining because the vent is above the aux tank. ill put a couple pix up when i get the chance.

 

[Shadrach]

I just got back from a 3300 km ( 2000+ miles ) trip and I figured I saved about $80 not having to buy fuel at higher prices. I used up half of my aux tank on the way there ( to get me thru an expensive spot ) and then bought fuel at a place just before I knew it was going to cost more and used the other half of the aux to get me back home. There are different ways to use the aux tank of course and to each their own. I like having the gauge and the manual valve worked fine, even when I forget to shut it off. I would "refill" the lower tank while at a campsite, so I never drove with it open except at the very end of the trip to drain the tank. I think I will just forget about the electric version save some cash and use the switch for something else, like canopy interior lights. Shad