Adding a Side Tank - Alternate Filler Method - Defender Source
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Old October 24th, 2004, 10:05 PM
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Adding a Side Tank - Alternate Filler Method

I'm installing the Euro-Spec under seat tank as an auxiallary tank during my Tdi conversion and I've wrestled with how to deal with filling it.

There is a write-uo here on D-90.com that has a neat solution using old series parts. I wanted to avoid cutting the fender and sourcing the series parts, and the different appearance of the two filler locations (stock and secondary) did not appeal to me.

Along similar lines, I could have cut another hole in the fender and used standard Euro filler parts. Again, I didnt want to cut, and the second hole would have had a squared top where the stock location i arched (anal I know) so that didnt appeal as much. Additionally, the filler tube fouls a roll cage brace running under the body.

This is what I came up with. I blanked off the filler using a hose cap from home depot (I'm assuming this will work, otherwise I'll be pulling the tank and welding a cover plate).

I then ordered a sweet aero filler cap from batinc.net (a supplier of aircraft parts and Ford Scorpio parts?), cut a hole, and installed the cap in the dead space.

Of course this requires lifting the seat base and access hatch to fill the tank, but since this is a diesel with good mileage and and auxillary tank anyway I'm not concerned. Plus I just like the cap.
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  #2  
Old October 24th, 2004, 10:38 PM
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Great idea, but good luck keeping the smell of Diesel out of the cab.
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Old October 24th, 2004, 10:46 PM
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Ah just like a series I.

Just to check but does a diesel nosel work with that filler . . . .
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  #4  
Old October 25th, 2004, 03:49 AM
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Very neat solution. I can get 700 miles range with my twin tank set-up.
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Old October 25th, 2004, 07:01 AM
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Thanks guys, two points-
1) I'll be using bio diesel almost exclusively so the smell isnt that big a deal (but I hadnt thought of that, though, I'll have to investigate the best seal I can for the hatch)

2) The filler hole is 1.75 inches across, I'm pretty sure a nozzle will go in there...
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Old October 25th, 2004, 12:21 PM
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Jim, if you had room, you could have welded a filler pipe on top of the tank, and routed it out to the back wheel well. Just leave the pipe stuck up as high as you can under the bed to make sure it doesn't get hit. This is the way the aux. tank was on the defender I sold a couple of months ago. Then you don't have to worry about dropping smelly diesel inside the truck.

Chris
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Old October 25th, 2004, 12:29 PM
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Thats true, and if this method sux, I'll try that next.
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