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08.06.2021 5:36:09
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If you have a generator that only has enough fuel capacity for a single gallon of gas, it probably only runs for a good 2.5 - 3 hours tops. That just does not cut it for most emergency situations or when you need to leave the generator running for long periods of time. Here is how you can make an auxiliary fuel tank to feed your generator.
Things You'll Need:
3 1/2 gallon or 6 gallon marine gas tank
2 marine gas tank fittings (black pastic)
2 brass marine fittingsfor gas tank
marine hose w/squeeze ball
2 small hose clamps
Drill
1/2 diameter hole bit
Extra cap for your generator (optional)
silicone sealant (optional)
1
You can get all of the materials you need at a WalMart Super-center or boating supply company. Purchase a marine gas tank (mine is a 6 gallon), 2 plastic marine fittings , 2 brass fitting, and a marine hose w/squeeze ball. You may optionally order an extra cap for your generator from the dealer or manufacturer, but I just used my original gas cap. Total cost was approx $55.
2
Lay out all of your parts. Look a the picture for reference of the parts.
3
Take one of the brass fittings out of its package and connect it to the marine gas tank you purchased. The importance of purchasing a marine gas tank is that it has a special vent system and a special line hook up attachement. See the next step picture.
4
Take your black plastic marine gas connecor and fit it over the brass fitting on your tank. See picture.
5
Here is an image of the gas can - see the large vent on your left - open this vent.
6
Take your gas cap off of your generator and place it on a solid table or on a concrete floor with a scrap piece of wood under it.
7
Get your drill and 1/2 hole bit and drill a 1/2 diameter hole directly in the center of the gas cap. Drill straight and slowly. YOU DO NOT WANT TO MAKE THE HOLE ANY BIGGER THAN 1/2 in diameter, otherwise you will need to caulk it up.
8
Screw the second brass marine fittings into your generator cap through the hole you just drilled. If you drilled the hole correctly, there will be enough plastic left to grab onto the threads of the brass fitting and it will tap itself into the hole. If not, then you have to use silicon caulk to seal up the hole to hold the fitting. I did not have to caulk mine, so you will not see that in the picture.
9
Another picture of the generator cap.
10
Now take the second black plastic marine gas fitting and put it over the brass fitting on your generator cap.
11
Screw your generator gas cap with fitting back onto your generator.
12
Set the marine tank beside the generator at least three feet away if possible.
13
Get your marine ballpump and hose. This is going to be the line you connect the tank and the generator with. Before connecting it up, look for the direction arrow on the pump, and install the pump with the arrow going to the generator - this is the gas flow.
14
Install one end of the marine hose with the squeeze pump to the fitting on the gas tank. Use the small hose clamp to secure it onto the fitting in case you have to move the tank around.
15
Make sure the hose is connected tightly to the tank.
16
Install the other end of the marine hose to the new fitting at the top of the generator gas cap. Use the seconde hose clamp here to secure the hose. Generators vibrate like made, and you do not want the hose to come off. I took it back off of the generator for a better picture to show you.
17
Here is what your setup should look like right now.
18
Give the squeeze ball two to three good pumps to prime the line. This works best if you already have a full tank of gas in the generator, but it is not necessary. The theory behind how this works is that the engine will suck the gas through the marine hose.
19
Run your generator, and enjoy the fact that you probably bought yourself a few more hours of run-time and less refueling
trips
Place your equipment at one common place. Now take one of the brass fittings and connect to the marine gas tank. Make sure that you buy a tank which has a pressure vent system and a special attachment through which you can hook up a line. Any normal marine tank will have these accessories. more
The second brass fitting goes into the cap opening. If you take care of the dimension, the brass connector should be an exact fit. If it is not, you can use a silicon caulk to shore up the extra space. The second black plastic marine gas fitting goes on top of the brass fitting.
The procedure of adding an auxiliary fuel tank is not that complicated and with proper supplies, it can be done within an hour tops.
Most of the household generators have relatively smaller fuel tanks which can provide support up to 2-3 hours at maximum. This can be a bit of a problem if you want to have an uninterrupted supply of electricity. To solve this problem, you can either operate two or three generators in parallel while ensuring that the load transfer is swift or go for the cheaper and one-time method i.e. to increase the fuel holding capacity of the generator by adding an auxiliary fuel tank.
Step 1.
Remove the inner workings of the fuel cap and drill out the center to fit the connector. Be careful to not drill the hole too large. It should be slightly under sized to allow the fitting to be screwed into the plastic cap.
Step 2.
Fill a thin amount of epoxy around the threaded base of the fuel line fitting inside the cap and screw on the female brass hose barb. Allow the epoxy to dry and them replace the rubber gasket inside the cap. The hose barb may or may not be needed but it makes the connection fitting stay in tight and I beleive it will help to draw the fuel into the generators built in tank.
Step 4.
Fill the fuel tank with gas, fill the generator built in fuel tank with gas, connect the fuel lines and start the generator. Be sure the vent on the fuel tank is open. That's it. [links]
The first thing that I did was to buy a spare cap for the built fuel tank in case I messed up doing this, or if I wanted to run without the extended tank. I found it locally for $15.00 from a Honda dealer in the area. Next was to get all of the miscellaneous parts. We decide on a 3 gallon tank instead of the larger 6 gallon since we don't run the generator that much. We already have a 3 gallon tank for the dinghy outboard so this could also be used as a spare. We also decided we wanted to be able to use the same fuel line as the dinghy outboard so we would not have to carry different fuel lines and again it could do double duty. To accomplish this we would need the attachment fitting that would be the same as on the one on the dinghy tank and on our Johnson Outboard. The two fittings totaled about another $15.00 and then another $4.00 for a brass hose barb. The plastic fuel tank was another $25.00 (please read this review before purchasing Moeller fuel tanks). The assembly was pretty easy.
Adding an auxiliary fuel tank to a generator may be necessary in the case when your current generator is unable to operate on its single tank. The addition of an auxiliary fuel tank allows the generator to continue running once fuel has been depleted from the main fuel tank.
A boating supply company or store like Wal-mart carries the materials you need to build an auxiliary tank. These materials, which are used in boating, are designed to provide you with the ventilation and exhaust needed to properly transfer fuel to the generator, once connected, and avoid an explosion.
The installed auxiliary tank will pump fuel into the existing tank when needed. You can manually pump fuel into the tank by pumping the squeeze ball. The auxiliary tank provides a way to provide additional fuel to the generator and keep it running regularly. You can get advice and detailed instructions on installing the auxiliary tank at the marine store or any fuel supply store. [links]