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Old 03-28-2021, 10:24 PM #1
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Auxiliary tank install on 99 4Runner

Here's my latest 4Runner project. Adding an auxiliary fuel tank where the spare used to go. I was going to use emkeith's Ford F150 tank kit - but when Habanero got me the kit for Christmas I quickly realized that the 4XInnovations rear bumper was taking up some of the room that the Ford tank would have needed. It has some sturdy diagonal supports for the receiver hitch that fill in the rear corners of the spare tire area. Had to return that kit and start planning something else. So I measured the room I did have (taking note of the front right corner being occupied by the exhaust pipe, as well as the receiver supports). And used google a bunch looking at lots of tanks to find the right combination of shape, size, filler location, pump style to suit the application. Pondered a poly fuel cell for a while - might be better able to handle the occasional scrape (???) but the proximity of the exhaust pipe made me decide to go with steel instead.

Eventually came up with a 56-57 Chevy fuel tank. 15.5 gallons, not too wide, deep, or long. About as big as I felt comfortable making fit, you could certainly squeeze a bit more tank in with more careful measuring and searching. 57 Chevy Fuel Injection Gas Tank - 570-CG - Affordable Street Rods

Since it's made for 'restomod' Chevys, it has accommodations for an in-tank fuel pump. Making the install a bit neater with no external fuel pump. I got a 255 LPH pump, should transfer the full 15.5 gallons to the Toyota tank in roughly 15 - 20 minutes or so.

First task was to chop out the spare tire holding crossmember. It just takes up too much room.
The mounts just consist of two pieces of 2X2 inch angle iron welded between the frame arms. The front arm got two slots carved into it for the tank straps, and the rear got two holes drilled in for bolts to hold that end of the tank. Cut them to length, fitted them in place, sort of wiggled things around for best fit, and then welded them in place. I probably needed to use a stick welder, but I've never gotten around to setting up our old Lincoln 'tombstone' stick welder (it needs 220V which we don't have in the garage). So I used my old crappy 110V MIG welder. Don't zoom in, it's not pretty. But it should be strong enough for the application...

Front of the tank. The lip of the tank (I had to straighten out a few bends) sits directly on the angle iron, the tank lip is about 1", and I used rubber stick on strapping to pad it there. The tank straps that came with the tank were too long for this situation, so I shortened them, looped them through the slots in the angle iron, and then I ensured they wouldn't wriggle loose over time by drilling a hole and bolting the loop shut.


Back of the tank. Same situation here - the 1" lip of the tank is cushioned by solid rubber tape - and enough of the angle iron sticks out past that to drill holes and hang bolts down for the straps. Fit the straps (also cushioned with the same rubber tape) and snug it all up firmly. This crossmember sits a bit higher than the front one - since this end of the truck is more likely to be dragged across ledges:




Connections to the Toyota tank: I decided to give it a go with the new tank sharing the Toyota tank's ventilation/carbon canister system. It's possible this won't work and I'll get a CEL, in which case I'll convert this to a vented style. But for the time being - two connections to the Toyota tank. A ventilation line - teed into the smaller vent line on the Toyota filler (my original filler was getting pretty crusty - so I bought a new cheapy one from Rock Auto as part of this project). A 5/8 line (close enough to the Toyota pipe's 16mm) that joins to the vent line on the new filler neck. And on the main Toyota filler hose (35mm) I used a radiator sensor adapter to add a 3/8 fuel line fitting from the Chevy tank's fuel pump. So when the pump is on - fuel flows through the 3/8 line at 255 LPH into the Toyota filler hose and on into the Toyota tank. All stuck together with the special fuel safe rubber hoses of various needed sizes:


I placed the new fuel filler on the rear fender - between the taillight and the stock filler door. It needs three hoses going to it - one large on (1 3/4") for the fuel filler to the Chevy tank (which is 2"), a 5/8 vent line to tie to the Toyota ventilation system, and a 3/8" vent line from the tank (to 'burp' it as it fills). This was a bit awkward - hole saws don't like going in at an angle. It was an ugly, brutal affair, but it got done.


Inside the rear fender area - here's the new filler neck. It has the three hose fittings needed - 3/8, 5/8, and 1 3/4. I had to chop some of the ventilation box that's located there, but I left the main functional part - the one-way flapper vale, in place and functioning normally. The neck angled downward quickly enough to clear the interior panel:


And the outside of the fuel filler. This is (I think) normally used on aircraft, so it's sleek and flush. I mostly wanted it so things could slide down the side and not catch on it, a different sort of 'aerodynamics'. It's a Newton Aero 300. I searched around and found a wide range in prices, the cheapest one I could find was a company selling them for Caterham kit cars (modern Lotus Super Seven clones). So it says 'Caterham' on it. A hole saw and 6 smaller holes, it bolts right on.


It's lockable, flip the lever up, turn, and the cap pops out and is retained with a little cable:


A side view of the tank showing how well it's tucked up between the frame rails. I don't think it will ever get dragged, if so, it will likely just dent and not leak - it's soft steel, pretty malleable:


And last but not least - the electrics. I was originally planning on having a switch up front, but then I thought that maybe that would just lead me to turn it on, and then forget to turn it off, leaving the pump running on a dry tank, etc. So I decided to just put a switch back in that corner. When I want to transfer fuel from the aux tank to the Toyota tank, I'll just stop, roll down the rear window, flip the switch, and wait. No real need to do it on the fly.


For future reference, I do have a gauge sender in the tank - wired up and stubbed out sitting behind that interior panel. The sender is specced (and reversed from normal) to work with the Toyota gauge in the dash - I'm planning on some point at running wires up to the dash and using an A/B selector switch to flip the gauge between the Toyota and aux tanks. Another future added feature will be a selector valve on the aux tank that switches it from filling the Toyota tank to an external hose - so I can fuel other vehicles easily if needed.

This was all a lot of work just to avoid lashing red plastic fuel cans up on the roof rack on our annual overlanding desert trips...


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Old 03-30-2021, 09:50 AM #2
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Filled the aux tank with 14.5 gallons yesterday. The main issue was 'burping'. Obviously the vent line on the tank isn't quite big enough, it's a 3/8 rubber hose that runs from the top of the tank (a flush fitting on the pump module) up to the filler neck near the cap. But you have to fill it *very* slowly, or it will splash a little gas out of the filler ever gallon or so. Pretty annoying. But... I guess a little less annoying than dealing with plastic gas cans jostling around up on the roof rack.

I let it sit with the 14.5 gallons in it for a while, checking for leaks. Nothing. Flipped the switch on to start transferring fuel, as expected, it's not all that fast, but it filled the Toyota tank from about 1/8th on the gauge to a bit over half in about 6 or 7 minutes. One slight leak found on the Toyota vent tube - a crappy hose clamp that was 'tight' (wouldn't turn), but wasn't really all that tight on the hose itself. Replaced it, all dry.

I wish it would fill a bit better, but I guess it is what it is. There is another unused fitting on the fuel pump module - the return line for a fuel injection system. I just have a plug in it, I guess I could use that as an additional vent and double the airflow out of the top of the tank. I'd just need to take the tank all the way out, to remove the fuel pump module, so I could trim the return hose - IIRC it sticks down about halfway inside the tank.
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Old 04-01-2021, 12:46 AM #3
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Quote:
Originally Posted by JohnMc View Post
Filled the aux tank with 14.5 gallons yesterday. The main issue was 'burping'. Obviously the vent line on the tank isn't quite big enough, it's a 3/8 rubber hose that runs from the top of the tank (a flush fitting on the pump module) up to the filler neck near the cap.
this is a pretty cool mod you've done. would a larger-diameter vent hose help the burping? also, sorry if i've missed it: is it valved in some way so you're not always smelling gas from near the filler neck?
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Old 04-01-2021, 08:42 AM #4
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Quote:
Originally Posted by photoleif View Post
this is a pretty cool mod you've done. would a larger-diameter vent hose help the burping? also, sorry if i've missed it: is it valved in some way so you're not always smelling gas from near the filler neck?
I'm just limited to the fittings on the tank. Unless I start drilling into the tank and adding new ones, which I probably won't do.

And I have tied this tank into the Toyota tank vent system - so it will share the Toyota charcoal canister vent system. The new cap itself is non-vented.
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Old 04-01-2021, 01:13 PM #5
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Something that I've been wanting to do. Was going to start down the and had the F150 tank route but ran into the same space problem with 4XInnovations bumper. I had the same plan for the filler too, although hadn't dug deep enough to find a good one like that.

Currently carry 2 x 5gal jerry cans on the 4X bumper (awesome bumper by the way, how it survived with all that weight through the stuff we did amazes me). I did have to use both cans and barely made it to fuel, ended up putting in 18.04 gallons. Having just a little bit more and shifting the weight down lower would be great.

Nice write up, gonna keep this info handy.

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Old 08-05-2021, 11:16 AM #6
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This worked great on our annual 2 week Colorado/Utah trip. I was wondering if tying the aux tank to the stock Toyota vapor recovery system would be work. I know issues with that system (like leaving a gas cap loose) can set CEL's, but over 3500 miles of use, up tall mountains in CO and in the UT heat, and with some steep ups and downs on some trails (Rose Garden Hill being probably the most difficult, but Elephant Hill has some steep parts as well) - no issues at all.

We did several days in the Maze District backcountry, made it back to civilization with about 1/8th of a tank in the main, and around 7 gallons left in the aux. I was saving some in case my wife needed it in her '96, but she made it to the station on fumes after adding 5 gallons from gas cans on the roof rack.

Dragged the bumper here and there, no issues with anything touching the tank.
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Old 04-16-2022, 10:49 AM #7
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Inspiring thread!

I'm in the process of amassing parts and a plan and leaning towards this tank and pump combo.

tank and pump

I, too will be running 2 tanks to skip the jugs and extend my range, refilling my factory tank from the aux via a switch on the dash.

Might copy everything else you've done except the rear bumper, my choice will have to be compatible with the eimkeith crossmember, and several are.
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Old 04-19-2022, 10:46 AM #8
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Quote:
Originally Posted by octanejunkie View Post
Inspiring thread!

I'm in the process of amassing parts and a plan and leaning towards this tank and pump combo.

Please Wait... | Cloudflare

I, too will be running 2 tanks to skip the jugs and extend my range, refilling my factory tank from the aux via a switch on the dash.

Might copy everything else you've done except the rear bumper, my choice will have to be compatible with the eimkeith crossmember, and several are.

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Following... Aux Tank is the next mod once I get a rear bumper! That's quite a good deal for an 18 gallon tank with a pump!
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Old 04-19-2022, 04:09 PM #9
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In retrospect, it might have been worth the effort to reroute the exhaust out of that front/right corner of general area the tank is in. Then you could fit in a wider tank and haul more gallons. And yeah, any bumper that has room for EMKeith's tank kit allows for a longer tank as well.

About the only thing I've done since then was add a 2 way valve and an extension hose so I could pump gas either into my main Toyota tank or to something else (like our lawnmower, or my wife's 4Runner outi n the middle of nowhere). I just coil the 3 or 4 foot hose up and tuck it in between the frame and body when not in use.

I still haven't bothered to run wires and get the stock fuel gauge to read either tank with a switch.
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Old 04-20-2022, 01:37 AM #10
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Quote:
Originally Posted by JohnMc View Post
In retrospect, it might have been worth the effort to reroute the exhaust out of that front/right corner of general area the tank is in. Then you could fit in a wider tank and haul more gallons. And yeah, any bumper that has room for EMKeith's tank kit allows for a longer tank as well.

About the only thing I've done since then was add a 2 way valve and an extension hose so I could pump gas either into my main Toyota tank or to something else (like our lawnmower, or my wife's 4Runner outi n the middle of nowhere). I just coil the 3 or 4 foot hose up and tuck it in between the frame and body when not in use.

I still haven't bothered to run wires and get the stock fuel gauge to read either tank with a switch.
I'm not keen to reroute my exhaust, but what other tank options could I be considering if I did, and if I didn't?
I already have the eimkeith crossmember in a box in my garage...

I've seen Hab's "self ejecting roof rack" I'd not trust that to carry gas cans either lol
BTW, tell her the FCC just reduced the GMRS license fee to $35 (from $70)

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Old 04-21-2022, 10:29 AM #11
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@JohnMc U possibly have a link the where u got the fuel mount/cap?

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Old 04-21-2022, 10:42 AM #12
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I got it from here: Aero Filler Cap & Neck Assembly - Black

It was cheaper a year ago. And when buying products from the EU/UK, if they're shipped elsewhere you don't pay the steep VAT, so it's the lower price. But yeah, that's not a cheap part.
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Old 09-14-2022, 08:13 AM #13
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Ironically, I ended up with the same 4XI rear bumper and found a slightly larger Tanks Inc tank for 49-52 Chevy I am considering

1949-52 Chevy Fuel Tank - Stock Capacity

Did you use a GPA series pump from TI?
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Old 09-14-2022, 08:31 AM #14
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Yeah, a 255 lph pump. It can empty the tank in about 10 minutes.
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Old 09-14-2022, 09:30 AM #15
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Quote:
Originally Posted by JohnMc View Post
Yeah, a 255 lph pump. It can empty the tank in about 10 minutes.
I found the same fill neck on Caterham's site. If it's a re-branded Newton it's like half price, even with the conversion from Sterling Pounds to US dollars + Shipping

Did you get a separate customs bill from the shipper?

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