Auxiliary Diesel Tank Filling

keeponvaning · Mar 2, 2020

Vandit said:
Could you post a parts list?

No. I found a metal frame at the dump that the tank just fit into and secured it with nylon wire ties. I would have used something more solid than wire ties when I actually installed it but I never did. I plan to use it on my new van but I won’t get around to that until Fall most likely- sorry?

TheVangineer · Mar 20, 2020

Hey @Vandit and @junkycosmos

Sorry for the delayed response here. Part quantities are going to vary a bit based on where you place your tank (mine is just behind the rear axle on my 3500 EXT.)

For the tank, I sourced from amazon. It's a nice tank, but I did cannibalize it a bit to add a vent port and a tank level sensor (still need to hook up the sensor to my monitoring system... but it's there). Tank is linked here. Mine is a 7 gallon, but they also make smaller and larger models so if you're willing to reroute your exhaust or relocate the spare tire, you could adjust accordingly.

For the filler neck, hosing, and connections, I used Filler Neck Supply, linked here. The tank I used has a 2" fill port, but I went with a more universal 1.5" filler neck and hosing, then converting to 2" at the fill spout on the tank. For the vent, I used a 3/4"tubing. I would take a look at filler next supply and get the mix of straight, 45 degree, and 90 degree hose lengths and associated couplers that you need. based on where you locate your tank.

Happy to talk more specifics if people are interested. While I love the functionality of this setup, it wasn't the cheapest thing in the world to rig. Not that it broke the bank, but I'd say I probably spent somewhere around $600 for the whole set up.

Vandit · Mar 21, 2020

That’s very very helpful. Thank you!

phil · Dec 10, 2020

For some reason I've been poking around this topic putting the pieces together in my mind.

Any who, this might work, but it needs a cover to keep the crap off it.

This one can't possibly meet the regs, both done by an off road upfitter.

el Jefe · Dec 11, 2020

phil said:
For some reason I've been poking this topic putting the pieces together in my mind.

Any who, this might work, but it needs a cover to keep the crap off it.
View attachment 69516
This one can't possibly meet the regs, both done by an off road upfitter.
View attachment 69517

I get blinded looking first picture. Can't decide whether it is the filler neck or the 30 amp shore power that looks out of place.

phil · Dec 11, 2020

I'm going to end up doing something similar to what TheVangineer did. The Filler Neck Supply: Gas Filler Hose | Fuel Filler Necks has all the pieces.

wmsmitty59 · Jan 4, 2021

phil said:
I'm going to end up doing something similar to what TheVangineer did. The Filler Neck Supply: Gas Filler Hose | Fuel Filler Necks has all the pieces.

Did you ever complete this? I'm interested in doing the same. I'm just hoping someone has sorted out the best filler neck & cap for this type of install. The rest should be pretty straight forward. I'm thinking a flanged filler neck (vented) with a fill and vent hose going to the tank. Just not sure which filler neck would fit in the DEF location.

phil · Jan 4, 2021

wmsmitty59 said:
Did you ever complete this? I'm interested in doing the same. I'm just hoping someone has sorted out the best filler neck & cap for this type of install. The rest should be pretty straight forward. I'm thinking a flanged filler neck (vented) with a fill and vent hose going to the tank. Just not sure which filler neck would fit in the DEF location.

No, it got cold and I got lazy.

Tod · Feb 16, 2021

TheVangineer said:
Hey there Gab_D,

I've had this system installed, up, and running for a few months now and have been absolutely thrilled with it.

The only things that I'll say take some real thought is how you run your filler hose to the tank, and how you vent the tank. You'll see in the photos from my previous post that the tank is filled from the side, so your venting has to be such that you don't create an air bubble which gets trapped in the upper portion of the tan (your tank also just has to be vented to prevent it from pressurizing itself due to temperature/elevation/etc and combusting...)

Anyway, all in all I love the system, though living in NJ, I'm definitely telling gas station attendants to ignore the green cap all the time... Feel free to reach out if you want any additional details!

This is a great idea.. I was just wondering the best way to run a fill port. No way I want to fill diesel inside of the van. A few drops will smell forever. Been there before.

Can you list your parts list and tank info? Did you do the full install of did you hire it out.

Looking forward to hearing the details on this.

junkycosmos · Feb 24, 2021

Post 22 has a nice run down but I’m in if someone figures out a kit of suggested parts. Agreed on no diesel inside !

Brian_Scott · Mar 17, 2021

TheVangineer said:
Just wanted to post an update to this. After a bunch of research into undermounting fuel tanks, materials for fuel lines, and dialing in the right sizes for a compatible filler neck and fill hosing, I spent last night installing the filler neck, running the first bit of hosing, and staging the tank for installation sometime soon (selling my old van this weekend so taking some time to clean it up/get it ready for its new home).

I really love the way this is coming together so far though. More than anything, I appreciate how easy it's going to be to get this filled, rather than having to take an aux tank out of the van interior or worrying about running the main fuel tank too low.

View attachment 58300 View attachment 58301 View attachment 58302

Where did you get the diesel filler fittings?

TheVangineer · Apr 22, 2021

Sorry for the delayed responses here.

@Brian_Scott All the filler neck and line fittings were purchased from fillernecksupply.com. They've got pretty much everything you'll need to get this done. Check out post #22 on this thread for a better listing of the parts that I used.

@Tod Thanks! Yea I'm a huge fan of keeping all of that outside of the van as much as possible. Most of my parts are listed in post #22, but it's ultimately a matter of figuring out what you'll need based on tank location. As for the install, I actually own a conversion company, so I did this one myself, but with some careful planning there's no reason this can't be done on your own. The big parts to think about are how you're attaching the tank to the underside of the van, as well as optimizing the flow from the filler neck to the tank to minimize air entrapment and tank burping while filling.

junkycosmos · Apr 29, 2021

Anyone else taking this little project on, just in time for summer ?

Wondering about tank monitoring sensor .. which one folks have used here ?

Also for the fill port sizing, not seeing Diesel 1.5" on that site, just 1 3/4 or 2"
1986-2010 GM Flatbed - Work Truck Fuel Filler Neck 2" X 5/8" Vent (Diesel)
1-3/4" Cab And Chassis / Flatbed Fuel Filler Neck 3/4 Vent (DIESEL)

Above from Vangineer >>The tank I used has a 2" fill port, but I went with a more universal 1.5" filler neck and hosing, then converting to 2" at the fill spout on the tank. For the vent, I used a 3/4"tubing. I would take a look at filler next supply and get the mix of straight, 45 degree, and 90 degree hose lengths and associated couplers that you need. based on where you locate your tank.

wmsmitty59 · May 7, 2021

junkycosmos said:
Anyone else taking this little project on, just in time for summer ?

Wondering about tank monitoring sensor .. which one folks have used here ?

Also for the fill port sizing, not seeing Diesel 1.5" on that site, just 1 3/4 or 2"
1986-2010 GM Flatbed - Work Truck Fuel Filler Neck 2" X 5/8" Vent (Diesel)
1-3/4" Cab And Chassis / Flatbed Fuel Filler Neck 3/4 Vent (DIESEL)

Above from Vangineer >>The tank I used has a 2" fill port, but I went with a more universal 1.5" filler neck and hosing, then converting to 2" at the fill spout on the tank. For the vent, I used a 3/4"tubing. I would take a look at filler next supply and get the mix of straight, 45 degree, and 90 degree hose lengths and associated couplers that you need. based on where you locate your tank.

Any luck sourcing the filler neck itself? I'm sure I can figure out the rest but I'm stuck on figuring out which filler neck Vangineer used.

phil · May 7, 2021

wmsmitty59 said:
Any luck sourcing the filler neck itself? I'm sure I can figure out the rest but I'm stuck on figuring out which filler neck Vangineer used.

Take the PM filler area apart so you can see if the diesel filler needs an bend and to investigate how to mount it. Then go from there.

Universal Fuel Filler Neck 1.5" With Hose Fitting 1 1 2"

phil · Jun 1, 2021

Doing a little investigating so I can figure out the pieces.

The DEF hole and below is small void as indicated in red, it's a little bit deeper than the door step, there is a divider inside the void with large holes.
The screw holes (3), lime color line, bolt pattern is 2 5/8".
The yellow line is approx 2 3/8" diameter (a 2" sch 40 pvc pipe will just fit)
I saw a Transit that used one of their small trim moldings (blue circle) as a fuel door, clever.
There is a vertical hole inside to run fill lines, that hole starts 5" as measured from the bottom DEF hole and the gas line is at 7", and the it ends at 9".

phil · Jun 1, 2021

This is the vertical hole with the gas hose (just a bit larger than a quarter).
-Red line is the parking brake cable.
-Lime line is the vent hose.
-Blue line is a 3 wire cable that goes up to the vent hose.
-Aqua line is the 5 to 9 inch space I mentioned earlier,

phil · Jun 1, 2021

Removed the shield, the gasket has the DEF hose hole already.

orientation, left side is the front and top is the side of the vehicle.
-Looking up the hole, lots of space.

phil · Jun 1, 2021

I removed the b-pillar cover (be careful or you'll break the thingy's)
-Looking down from the inside.

the cover with the thingy's

moparkent · Aug 13, 2021

Here's my working filler and tank. I found a filler at the wrecker for $12. 1/2" connection with a 3/8" vent. I'd recommend fillernecksupply.com for a generic diesel filler neck unless you want to wander your local wrecker. I connected with three 45° Gates 24710 & one 90° Gates 24715 Molded Gasoline Fuel Filler Neck Hoses with two ICT Billet 1-1/2" to 1-1/2" Inch Hose Barb Splice Coupler (all on Amazon). I had to remove the splash guard underside and the access plate next to the driver seat (B Pillar). It took about six attempts to get the hoses cut to size and pushed up from underneath. I should have taken a picture of the bottom 45°s.
The tank is a custom spun aluminum gas tank from Sandstorm USA spunaluminumgastanks.com 4" x 26" with a 1 1/2" neck and 1/4" NPT fittings for vent and feed. The tank came with mounting brackets but I also fashioned 1/8"x3/8 flat steel 90° (2"x5") brackets attach the tank to the frame member behind the Promaster Charcoal Canister. Sandstorm USA was awesome to work with and if you want this tank the P/N is KC426HZ.
The tank volume is 1.4 gallons. For us, we have been using it for a month now and is plenty for us to use it every morning for about 30 - 60 minutes (2.0Hz on our heater). About two weeks worth on the Northern California Coast. It'll last about a week in the fall when we're heating at night, too.
I am using 1/4" poly-tubing on the feed with a tee to the vent, that way I can see the tank level. The poly-tube is holding up fine but I may replace the horizontal section with fuel line. The poly-tube feels like it may be getting stiff from the diesel reacting. I connected the fill hose to the tank bottom because the fill hose naturally sits at that level. Filling up at the pump is effortless but I have pumped slow.

Auxiliary Diesel Tank Filling

keeponvaning

TheVangineer

Vandit

phil

el Jefe

phil

wmsmitty59

phil

Tod

junkycosmos

Brian_Scott

TheVangineer

junkycosmos

wmsmitty59

phil

phil

phil

phil

phil

moparkent

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