I haven't seen it done on a Promaster.

 

Why not just get a gas version of the heater, and tap into factory tank?

 

Depending on the altitude for a gas version, you could be throwing your money away. Burners that soot up and can't be cleaned will cost you $400.00 to replace. Go the cheap Chinese diesel at 1/5 the initial cost. Carry a spare burner - 20.00?

 

I've used a propex HS200 heater in my previous build, but really looking to get away from propane. I really like the Espar D2 Airtronic heaters, have installed them in other vans (already diesel) and really appreciate the lower maintenance of a diesel heater relative to a gas fired option like the webasto. I'm sure they're just fine, just not my preference at this point.

I also really like that the Espar has the built in altitude sensing module to adjust the mix, as I'll regularly travel between sea level and around 8,000 feet.

 

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.

 

Where did you get the diesel filler fittings?

 

Very neat. When you get it all figured out how about posting the product list and/or offering a kit?

 

That's the plan! Will probably post another time or two along the way here with progress updates, but eventually I'll have a walk-through and parts list available.

 

i used the chinese diesel heater and mounted the tank that came with it inside. actually i paid reds custom design to do my install

 

here is picture of my aux diesel fuel tank

 

Looks like that came out nice and clean! For me, I had a few criteria which led me away from something like this:

1. Long-term climbing/skiing/mountaineering trips have me parked in an area for a week or more at a time, so I wanted to be able to carry a sizeable amount of fuel stored up, conservatively designed to be able to run the heater continuously for the whole time. For me, I determined this would require somewhere between 5-10 gallons.
2. I really didn't want to have to open up the van to fill the aux tank, and didn't want to mess with having a separate canister to act as a transfer tank.
3. After having a propane-fired heater in my last build (Propex HS2000), I hated how much space the propane tanks took up inside the van. With an enclosure under the bed, I lost about a third of the available storage down there. This won't impact my storage space at all and will only extend as low as the muffler, so no loss of clearance either!

Totally a matter of preference. I also couldn't resist trying something like this that I haven't seen done on any other vans as well....

 

Totally a matter of preference. I also couldn't resist trying something like this that I haven't seen done on any other vans as well....

Actually it was done on a Transit awhile back, but IMO his install turn into a money pit by having a custom tank built. His glad it's done, but won't recommend doing it his way. For Transit owners he offer this, "Word to the curious - be aware that this mod is very labor intensive".

I think for the Promaster it's a more straight forward mod as your showing.

Looking forward to your mod.

 

I installed mine inside in a sealed (gasket) plywood box. After 2 days driving we couldn't sleep because of the diesel smell. No matter how hard you try the diesel smell penetrates everything. We were on vacation, so I ended up pouring cat litter inside the box to absorb as much as possible the smell. I will now install it outside or simply using a small 5 L in the engine compartment as someone else did in this forum.

 

Mine is in the engine compartment. No way would I put it inside the van. Diesel smell is strong.

Sent from my Pixel 3 XL using Tapatalk

 

Mines inside for the last year and there is zero smell.

 

Just putting another update here on the progress of this install. I keep pushing this down the priority list in favor of continuing the interior build, but with the cold coming, it's time to get this checked off.

Welded up some custom brackets yesterday and mounted my 7 gallon auxiliary tank below the van. Tank fits pretty **** perfectly right between the spare tire and rear axle. Really happy with the way this came out. The assembly hangs a total of 12.5" below the underside of the floor, with about 4-5" still clear from the bottom of the rear axle. Now that the tank is in place, I can order the final length of fill hose to connect to the filler neck I had previously installed and it'll be all set! Standard heater installation beneath the passenger seat will be sometime this week, and hopefully everything will be up and running by the weekend!

 

Just wondering if you have any more updates, looking to do the same...

 

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!

 

Nice exterior diesel tank setup. I was wondering what / how you ran filler and vent? Also curious where you sourced tank, or did you build?

 

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.

 

That’s very very helpful. Thank you!

 

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.

 

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.

 

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.

 

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.

 

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 !

 

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.

 

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.

 

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.

 

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".

 

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,

 

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.

 

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