"Fuel-On-The-Fly" Reserve Tank Project I made a reserve vegetable oil tank to take on long trips with my Chevy Suburban. I've refined it over time and it is working so well I thought I'd share the results and plans to make one. Instead of trying to Filter-on-the-Fly my thought was bring an extra supply of properly filtered and dewatered oil with me and just pump it from my reserve tank into my onboard veggie tank at the push of a button. After the plumbing is down, I can install the reserve tank in 10 minutes and after my trip, remove it in about the same amount of time. It stays in storage between trips freeing up the space in the back of my Suburban for what it was intended for. Time: The project took me about 2.5 hours to complete and cost $225.00 not including tax and shipping. Since it costs me around $130.00 to fill up my Suburban on 1 tank of Diesel the payback for this reserve tank was very quick. Materials List 35 Gallon Poly Fresh Water Storage Tank-Container Once in the store search by keyword "35 Gallon Poly Fresh Water Storage Tank-Container" QYT = 1 Cost: $89.99 Source: http://stores.ebay.com/TANKS-MORE --------------------------------------------------- Shurflo Pump 1.0 GPM 12 VCD QYT = 1 Item#: 8009-541-236 Cost: $49.99 Source: http://www.northerntool.com http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_357081_357081 --------------------------------------------------- Nylon Tee Fitting QYT = 1 Item#: 62067 1/2" x 1/2" x 1/2" Cost: $0.44 Source: http://www.usplastic.com/catalog/default.asp High-Flow Quick Disconnect Couplings by Colder 3/8" Polypropylene In Line Hose Barb Shutoff - 2.82 Lgt - Coupling Body QYT = 2 Item#: 60688 Cost: $9.91 each Source: http://www.usplastic.com/catalog/default.asp 3/4" Polypropylene Male Pipe Thread NPT Shutoff - 1.76 Lgt - Coupling Insert QYT = 1 Item#: 60763 Cost: $7.86 Source: http://www.usplastic.com/catalog/default.asp 1/2" Polypropylene Hose Barb Shutoff - 1.86 Lgt - Coupling Insert QYT = 1 Item#: 60814 Cost: $7.61 Source: http://www.usplastic.com/catalog/default.asp --------------------------------------------------- 10-Ft. 12VDC Extension Cord w/On/Off Switch QYT = 1 Item#: Model: 270-1557 Catalog #: 270-1557 Cost: $7.99 Source: http://www.radioshack.com/home/index.jsp 10-Ft. 12VDC Extension Cord QYT = 1 Item#: Model: 270-1592 Catalog #: 270-1592 Cost: $8.99 Source: http://www.radioshack.com/home/index.jsp --------------------------------------------------- Any Auto Parts store Buy the following: 6' of 1/2" inside diameter rubber automotive hose 6' of 3/8" inside diameter rubber automotive hose Three 1" hose clamps Two 3/4" hose clamps Role of Teflon tape Shrink wrap tubing to seal the electrical connections after soldering the wires PVC Rubber gasket (Make sure the 1/2" inside diameter hose you buy fits inside the hole in this gasket Ratchet style hold down strap --------------------------------------------------- Tools you'll need Soldering Iron and electrical solder Scissors Tubing cutter or sharp knife 2" crescent wrench 1" crescent wrench Screwdriver Drill 3/4" hole saw --------------------------------------------------- Instructions Note: Photos are located here: http://66.92.19.165/wvo/Photos%20of%20reserve%20Veggie%20Tank%20for%20long%20trips/ Step 1: Remove the third seat from the Suburban. Have someone in the Suburban while you crawl under the vehicle. Assuming your veggie tank is on the Driver's side between the rails locate the filler neck and the rubber vent hose that runs along the filler neck. Now look up at the underside of the sheet metal where the third seat sits. Pick a spot and then knock with a hammer so the person above can mark the spot. Get in the back of the Suburban now and push down on the carpeting where you plan to drill through the sheet metal. You'll find metal ridges under the carpet. Choose a depression in the ridge and drill your 3/4" hole using a hole saw. You'll first cut through the carpeting so you'll have to stop and remove it several times from your hole saw. Once the hole is through insert the rubber PVS valve grommet into the hole. Take the 1/2" rubber hose and push it through the hole in the center of the PVC gasket. The PVC gasket will prevent the hose from getting cut from the sharp sheet metal. (Photos IMG_2278 - IMG_2282) Step 2: Crawl under the vehicle and locate the filler neck to your veggie tank. If you have similar tank as mine there should be a 1/2" ID hose between the tank and the filler neck. This hose allows the tank to breath while you are filling the tank. Take your hose cutters and snip out a 1.5" section of the hose. Insert the T-fitting into both hose ends and secure with clamps. Reach up and grab the end of the 1/2" rubber hose you pass through the sheet metal above and insert it in the end of the T-fitting. Secure with a clamp. (Photos IMG_2291 - IMG_2293) Step 3: Back in the Suburban, pull the hose up and then install a 1/2" Quick Release coupling (Male end) at the end of the hose and secure with a clamp. Reinstall the third seat routing the hose to the back area of the Suburban. (Photos IMG_2284 - IMG_2286 and IMG_2296 - IMG_2298) Step 4: Install at 3/4" Quick Release Coupling (Male end) in the reserve tank. (Photos IMG_2302 - 2304) Step 5: With a soldering iron, connected the 12 VDC pump to the Radio Shack 10 ft extension cord. Use heat shrink tubing to keep the connection dry. Attach the 3/8" ID rubber tubing to the pumping using the fitting that came with the pump. Use Teflon tape on the threads. on the end of the 3/8" hose install the Quick Release Couplings (Female ends). Connect the suction end of the pump to the reserve tank and the pressure side to the hose you plumbed to the onboard veggie tank. Use the Radio Shack extension cord to extend the 10FT cord you installed and run the wires up to your dash area. Plug the extension cord into your cigarette lighter. Make sure the On/Off switch is Off. (Photos IMG_2305 - IMG_2310 and 2365) Step 6: Fill the reserve tank with veggie checking for leaks. I recommend you turn the pump on and transfer oil from the reserve tank to the onboard veggie tank before you leave on your first trip. Check for leaks and remove the filler neck cap to make sure pressure if not building up in the tank. I have a self venting cap for my veggie tank and I had no issues. I chose the 1 GPM pump on purpose to insure the fluid transfer would be slow and give the tank a change to breath. make sure you unscrew the cap on top of the reserve tank 1/4 to 1/2 turn so the tank can "Breath" while vegetable oil is being pumped from it. Secure the tank with a ratchet style strap to insure the tank does not fly around in case of an accident. (Photos IMG_2312 - IMG_2317) This set up worked amazing well on my initial trip. I drove 985 miles round trip from the Bay Area to Southern California and did not stop for fuel one. "Fuel On The Fly" by pressing the small button on the cigarette lighter. The system was paid for in 1 trip! I hope this information was helpful!