Tag-Along Aux Fuel Tank (joe2lmaker)

Update 2011-03-01

Some of my photobucket pix got deleted. If you're interested in seeing all the pix to this thread clicky here https://candybutt.org/cba/node/90

<a href="https://www.fjrforum.com/forum//index.php?showtopic=25361&hl=auxillary+tank" target="_blank">joe2lmaker has been designing and building an aux tank for the FJR.</a> I was lucky enough to get SN1, a prototype, for testing. Yes, I paid hard money for this tank. No, I have no financial interests or investment in his aux tank endeavors. Yes, I paid less than full price - Joe has told me I paid less than it cost him to build. The trade off is that I'm testing his tank and providing feedback for future improvements, and the tank to me is 'as is'. My job then, is to report the good and the bad ("things needing improvement").

If you're OK with this, then, let's get going.

SN 1 arrives well packaged

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05040.jpg" border="0" class="linked-image" />

On the bench for initial inspection with the goodies too. The welds and bends are top quality, gorgeous.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05042.jpg" border="0" class="linked-image" />

Tank interior, it says so! Good baffles to prevent sloshing effect.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05046.jpg" border="0" class="linked-image" />

My first task was to fit the JAZ cap to the tank. SN1 required some modification, as the Jaz cap flange interfered with the vent bung hole weld. Here is the interference line. Joe has already corrected this on later tanks.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05072.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05048.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05081.jpg" border="0" class="linked-image" />

My sophisticated machining mill...

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05082.jpg" border="0" class="linked-image" />

The final product. I was chicken to reduce the weld. I don't have alum weld equipment, and I can always buy another flange if needed..

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05084-1.jpg" border="0" class="linked-image" />

The next thing to look at was the cap ring. I couldn't figure out what the purpose was for this. Supposedly, it fits inside the tank. I think it might be for tanks with a bladder. I saw no need for it, and haven't used it.. unless I find out there is a good reason to.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05085.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05086.jpg" border="0" class="linked-image" />

Ok then, let's mount this tank on the Gen2 06.

Provided are new collars for the primary tank mounts, to the grab rail. OEM on left, new on right. They are well done, nice machining.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05061.jpg" border="0" class="linked-image" />

Bolts pass through the hollow tubes for easy install. I bought some longer bolts so that there is a full 1/2" thread engagement.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05063.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05064.jpg" border="0" class="linked-image" />

Stock bolts are 30 mm I used 35 for more thread engagement. In hindsight, the stockers would probably be OK, but once full of fuel I'd rather have the additional threads.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05078.jpg" border="0" class="linked-image" />

On the bike, it fit perfectly - a huge thing.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05053.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05051.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05058.jpg" border="0" class="linked-image" />

Brodie just happened to be in the Hondarosa hood and wanted to see how his seat, which has been extended rearward to accommodate his long legs, fit. It's a custom Bill Mayer seat. The tab and hole at lower left is for the valve. What a great guy Brodie is.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05104.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05105.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05108.jpg" border="0" class="linked-image" />

The dude has some seriously long legs.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05112.jpg" border="0" class="linked-image" />

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05106.jpg" border="0" class="linked-image" />

As you can see, there is plenty of room for longer seats, Givi52's, etc.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05075.jpg" border="0" class="linked-image" />

I replaced the stock Jaz flange bolts

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05072.jpg" border="0" class="linked-image" />

with some nice stainless button heads. Not needed, just nicer.

Finally, I added water to the tank to check for leaks and see what the additional weight felt like when riding.

<img src="https://i75.photobucket.com/albums/i320/dcarver220b/FJR/Aux%20Tank/DSC05143-1.jpg" border="0" class="linked-image" />

Couldn't test it because of a <a href="https://www.fjrforum.com/forum//index.php?showtopic=126868&st=0&p=715542entry715542" target="_blank">stoopid mistake.</a>

If you have any questions, please ask. I'll answer honestly.

to be continued

Nice setup, wha't the total capacity?

Why did he give it to you to try? Seems like, given you're the President of the CBA, you may need to fill up again in what, June of 2015?

Thanks dcarver,

This is the report I've been waiting for! Really interested to hear how the tank works in real world use...does it gravity feed reliably and how long does it take....but I suppose you're getting to that. So I'll shut up and watch. Beautiful tank.

BwanaDik said:

Nice setup, wha't the total capacity?
Why did he give it to you to try? Seems like, given you're the President of the CBA, you may need to fill up again in what, June of 2015?

Click to expand...

Hmmm, total capacity = IBA IBR legal, which, if IIRC, is 11 gallons? OK, found it - 4.797 gallons. Oh, and the June of 2015 crack, well, :****: and :rofl: yep, I'm gonna find me the one cheap gas station, fill up, and be good for an entire year!

Good2Go said:

Thanks dcarver,This is the report I've been waiting for! Really interested to hear how the tank works in real world use...does it gravity feed reliably and how long does it take....but I suppose you're getting to that. So I'll shut up and watch. Beautiful tank.

Click to expand...

I'm anxious to see too - I've PM'd one a feller from the forum who has some gravity tank experience, and has done a few non-CBA rides in his life, it appears pretty much every gravity feed tank has some quirkiness as to when best to start a transfer, main tank pressure buildup, restrictive fuel filters, etc. More to come.
In the meantime, I need to order my bulkhead fitting and some other hardware. I'm a bit nervous about drilling the main tank.

Looking at that it seems that it would be really easy for joe to make a Tanji style tank and sell a bunch of them.....

P.S. nice write up Don.

P.P.S. are we on for lunch on Sunday?

R

Just purchased some hardware for the tank.

Quick disconnect fittings (I used 5/16" id for max flow, less restriction)



and this bulkhead fitting-



From a KaitsDad post, 2006, he used this Loctite stuff, so I need to source it and also the cool blue fuel line he used too.

Note the Loctite 567 sealant on the threads - if you use this stuff, please remember to use the recommended primer. 567 PST Thread Sealant High Temperature You will need to enter "567" in the search field for the info. I used this on the penetration fitting, the tank petcock, and even the vent tube fitting.

Click to expand...

Fairlaner said:

Looking at that it seems that it would be really easy for joe to make a Tanji style tank and sell a bunch of them.....

Click to expand...

:swoon2:



I made a Tanji style tank. I used it when I went to CFR last year. I decided I would rather have this.

I tried to sell my Tanji style tank so I could put the funds toward this project. <Link to classified ad>

I still have that tank. I cut the Coyote Gear filler neck off and I have a custom filler neck to replace it. My plan was to put it in the classifieds again, but I'm doubting there is any interest.

Joe2Lmaker said:

Fairlaner said:

Looking at that it seems that it would be really easy for joe to make a Tanji style tank and sell a bunch of them.....

Click to expand...

:swoon2:

Click to expand...

So maybe a silly question for you Joe.....a man of your obvious talents why couldn't you just mount your trunk on top of that tank?????

R

Joe2Lmaker said:

Fairlaner said:

Looking at that it seems that it would be really easy for joe to make a Tanji style tank and sell a bunch of them.....

Click to expand...

:swoon2:

Click to expand...

Having stood out in the rain with mad's flashlight while you showed me that tank and the clean fitting set up, and assuming the new neck will fix the cap leak that aggravated you, I'd buy it if it fit a Gen.I. But alas! I can't figger why a Gen.II feller wouldn't buy it. Oh yea -- there was something about the Gen.Is not only bein' faster, but attractin' higher IQ folks too?? :lol:

dcarver said:

I'm anxious to see too - I've PM'd one a feller from the forum who has some gravity tank experience, and has done a few non-CBA rides in his life, it appears pretty much every gravity feed tank has some quirkiness as to when best to start a transfer, main tank pressure buildup, restrictive fuel filters, etc. More to come.

Click to expand...

Just put a pump in it Don & be done with it.

Fairlaner said:

So maybe a silly question for you Joe.....a man of your obvious talents why couldn't you just mount your trunk on top of that tank?????
R

Click to expand...

That is not at all a silly question. I could easily make a razzle dazzle mount that would accept a trunk, but I got to thinking...

I tried to talk my wife into joining me at CFR. I told her I would pay for her to fly-in, take the train, or whatever floated her boat. She declined, but if she ever does accept that offer, (like to Key West for example) I will need to ditch the tank, and put her seat on. If I have a tank like the Tag-Along, she can bring her seat and we could store the tank while she enjoys my company and some great riding roads (unless it's Key West - of course). Then, I put her back on the plane, seat in hand and I put my tank back on. The grab rails and trunk won't be affected by any of this.

If that's not love, I don't know what it is. ... (co-dependency? fear of abandonment?)

exskibum said:

Having stood out in the rain with mad's flashlight while you showed me that tank and the clean fitting set up, and assuming the new neck will fix the cap leak that aggravated you, I'd buy it if it fit a Gen.I. But alas! I can't figger why a Gen.II feller wouldn't buy it. Oh yea -- there was something about the Gen.Is not only bein' faster, but attractin' higher IQ folks too?? :lol:

Click to expand...

That brings back memories!

Barb and me, too shy to talk to each other... MEM reading my name tag slowly and without recognition, then asking "Do you post often?" Good thing my wife never reads this forum.

What were we talking about??

Oh, yeah, Right, The problem with the cap. I wanted a locking cap and the locking cap I bought from Coyote Gear was terrible. There is NoWay that thing fits their filler neck. The new filler neck will accept a locking cap and I put all the details beginning here <Link> and details for the solution here <Link>

Gramps said:

Just put a pump in it Don & be done with it.

Click to expand...

Patience grasshopper. There is a method to the madness...

Ahhhhhh grasshopper....I didn't notice that the grab rail was missing, of course if she is carrying that seat it would not be much harder to carry the grab rail also...

R

Joe2Lmaker said:

Patience grasshopper. There is a method to the madness...

Click to expand...

Ahh wise one, where there is darkness your presence shines brightly to guide the way.

Fairlaner said:

Ahhhhhh grasshopper....I didn't notice that the grab rail was missing, of course if she is carrying that seat it would not be much harder to carry the grab rail also...
R

Click to expand...

Your power of reason is useless on me Batman!

When I built the fuel cell for mine I was thinking like Joe in that it needed to fit with out any changes to the bike. If I need to carry a passenger it takes less than 5 minutes to change over. His is a much nicer looking unit but mine hides under a cover so it doesn't show. I would add that once you have a fuel cell you get spoiled with the ability to fuel when you feel like it. I built mine after getting stuck in Utah and paid close to 5.00 a gallon while MM2 just grinned and turned the valve and waited. He got gas down the road at a much cheaper price.

Fuel line routing..

My first thought was to use 5/16 id hose for less restriction. Then I tried routing that fat hose and realized what a PITA it was. I recalled KaitsDad saying he used 1/4 plastic so the bends could be tighter... and I gave up on 5/16 for now.

Here's a pix of my proposed 5/16 routing..



And the 1/4 plastic routing -



The plastic hose is so much more workable...

After all is done, I may try to find 5/16 plastic (heat resistant, gasoline proof, yada yada yada) *if* the 1/4 doesn't adequately flow the main tank. I'll cross that bridge later, if the problem exists.

On a side note, not much sleep lately, server issues at work and long nights.

Good night RenoJohn-Boy!

dcarver said:

*if* the 1/4 doesn't adequately flow the main tank. I'll cross that bridge later, if the problem exists.

Click to expand...

Don with 1/4" ID I had no problem with transfer speed on mine, ...but like you I'm going to attempt 5/16 this time around. In fact, I'm looking for an easy-snap connection that will accomodate 5/16" if you have anything in mind, or run across anything, please let me know. Currently with the 1/4 i've been using this(clicky) ....and don't laugh, it has really held up and worked well for many miles.

dcarver said:

Good night RenoJohn-Boy!

Click to expand...

Looks good Don ...I really like the way Joe incorporated the petcock into the design. groovy.
I am completely re-doing mine and look forward to sharing pictures etc. It's all powder coated now and installed on the old bike, incorporated 3storage options as well as flat design so it will be very versatile. I need to move it over to the new bike, but maybe I'll take some picturest first. Like you, juggling a lot of stuff.

keep us posted, looks pretty groovy.

...and good night to you Donnie

Nice job on the aux tank Joe.

Just wanted to confirm that this tank will fit with a Givi bracket installed instead of the OEM grab rail - is that correct? From the pics it looks like it will since the Givi bracket is only a little narrower.

dcarver said:

After all is done, I may try to find 5/16 plastic (heat resistant, gasoline proof, yada yada yada) *if* the 1/4 doesn't adequately flow the main tank. I'll cross that bridge later, if the problem exists.

Click to expand...

It's routed a little different than the way I would do it, but I still don't have any photos. (and I gotta get to work)

JamesK said:

Nice job on the aux tank Joe.Just wanted to confirm that this tank will fit with a Givi bracket installed instead of the OEM grab rail - is that correct? From the pics it looks like it will since the Givi bracket is only a little narrower.

Click to expand...

Yes. You can see photos <here>

I think I have the attachment figured out too. It should be pretty simple, but the existing fasteners through the Givi will need to be replaced. PM me and I'll go into more detail.

Edit:

You can see the scribe lines where I originally wanted to mount the drain. There was some interference there, so I relocated it.