My saddle tank project (tech)

[fishuntr]

Well, i did it with no "Boom". You recall, i wanted to mount my saddle tanks, but with a few modifications.
1. I didn't want to cut holes in the side of my nice pickup bed.
2. I wanted to be able to fill both tanks from one side.
3. I didn't want to blow myself up in the process.
Here's how I've done it so far:

First, let me admit, i have a son who is a professional welder/fabricator. We did all of the welding in his shop at Performance Fabrication in Apple Valley. I DID do all the planning, cutting and prep, but left the actual welding to him. (Remember; "old & wise" )

I cut the fuel fill pipes off from their original locations, which had them up in between the inner and outer bed sides in front of the rear wheels. I welded patches over these holes and welded short pieces of 1/8" steel pipe nipples into them for vent hoses.

Regarding the "no boom" part, I cleaned the tanks , then filled them with CO2 and kept the CO2 flowing during each welding sequence.

I cut notches in the fuel fill pipes so they would fit over the corners at the top/rear of the tanks. The tanks don't extend very far into the rear fender wells, so I angled the fill pipes for easy access. The fill pipes are 2" OD, so i cut the holes with a 1 3/4" hole saw and custom fitted them with a grinder. The fill pipes were then welded in place


There wasn't enough clearance on top of the tanks for a crossover fill pipe up there. I cut a 3/4" steel pipe coupling in half and ground it smooth on the sides, leaving the "collar" on the ends. Using a hole saw, I cut holes in the rear ends of each tank at the bottom. I then welded the 1/2 couplings into the holes in each tank. Once the tanks are mounted, I will put two 90 degree brass "3/4 pipe to #12 hose" fittings in them and fit a crossover hose between the tanks.


The crossover hose will allow me to fill both tanks from one side
(either side). The two saddle tanks will become, in effect, one tank. I will only use one tank's pickup tube and route the fuel line to a two-way selector valve. The seat tank is one position
of the selector,and the two saddle tanks, acting as one, is the other position.

Regarding the vent hoses, I will put a small fuel filter in line, just to keep dirt, water etc out. I will route the vent hoses over the top of the frame rails.

I have to clean the surface of the tanks, paint them, mount them in place and hook up the fuel lines. When I get finished I will post some more photos. If anybody has questions, just fire away, or email me.
Jimmy James




Former fill pipe hole with patch ready to weld


Former location of fill pipe was patched and a 1/8" steel pipe nipple was welded in for a vent hose


CO2 slowly and constantly flowing into tank


Fill pipe relocated to end of tank


1/2 of a 3/4" steel pipe coupling welded in bottom at rear of tank, for fuel transfer/equalizer hose