Aluminum Subtank Under $300

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Veggie80

Veggie80

Joined
Feb 16, 2007
Threads
15
Messages
184
Location
Ft. Collins, Colorado
Website
www.green-logic.net
Here is an Aluminum 26 gallon subtank that will fit the 80 series and can be done under $300.. The tank came from www.rdsaluminum.com and the dimensions are 36 1/2"L x 16 3/8"W x 10 3/8"T and cost $230 shipped it can be used for gas, diesel and veggie oil.. I put a locking fuel door from a Jeep wrangler 97-07 and they can be found in junkyards or ebay for under $50.. We had to cut a hole in the passenger side rear fender and another hole in the underside of the body to run the filler hose and mount the door..

Mounting the tank we decided to support it from the ends with brackets welded to the frame and a tab for the tank to bolt to..I doesn't seem to hang any lower than the factory spare and might even be a littte higher up..When I do a rear tire carrier I will put a skid plate running from the bumper and under the entire tank to protect it from a direct rock shot.. I weighed out all my options for another tank and this way seems to be the best way to go for the $$$..I'm really stoked on how the billet fuel door came out almost looks better than the factory one...

I also needed to use aluminum for my veggie system and it keeps the overall weight down..The tank will not transfer fuel to the stock tank, but will have a secondary fuel system controlled by a switching solenoid......Here's some pics!
subtank1.webp
subtank2.webp
subtank3.webp
 
NICE!!! that fill port does look sweet on there. good info to have, seems like lots of folks could do w/out the fuel trasfer capability for the cost savings. Now i suppose youd have to be game w/ cutting a hole in the rear panels, but not much different than a snorkel.
 
You can use a little body saw or jig saw to get through the fender although it was thicker than we thought..They put some factory rubber matting on the inside of the outer body, maybe for sound dampening.

Not sure on the clearance..I think it's higher than the factory spare and definately higher than the Long Ranger..Anybody got a measurement from level ground to the lowest part of the factory spare? I'm definately gonna put a steel skid on it, because that aluminum is soft and won't take any impact well.
 
nice!

(even nicer if they could put a chamfer on the rear lower edge to make that end a bit higher.)
 
I can take more pics of the backside of the filler door... The tank can be removed by unbolting and lifting up and sliding to one side of the other..Then you can drop the tank completely out..The skid will be bolt on so the tank can still come out if need be..
 
I am not a party crasher but you should know that Toyota doesn´t aprove ANY welding to the boxed frame after the cruiser were assembled !!!!!

The steel type used to do the frame allow some flexing which is compromised once you weld it.
 
robmir said:
I am not a party crasher but you should know that Toyota doesn´t aprove ANY welding to the boxed frame after the cruiser were assembled !!!!!

The steel type used to do the frame allow some flexing which is compromised once you weld it.
Click to expand...

I don't think toyota approves of cummins conversions either. People weld sliders on all the time.
 
Forgive my ignorance, but would it be possible to use a dual neck filler if you weren't segregating fuels and just looking for extra range? Also, can you post a picture of the inside of the fender where you put the new filler neck?
 
Excellent work! This is a great solution for a second fuel tank if you're not hooked on the expensive dual filler neck and oem tank setup. Though, for a second fuel tank I'd stick the fill on the same side as OEM!!
 
Please more pics: Inside the quarter panel. for the fuel fill routing. How many gallon tank is that? Is it baffled? Do you have pics of it prior to install?

Thanks,
Dave
 
alia176 said:
Excellent work! This is a great solution for a second fuel tank if you're not hooked on the expensive dual filler neck and oem tank setup. Though, for a second fuel tank I'd stick the fill on the same side as OEM!!
Click to expand...

One benefit of being on opposite sides is that you don't have to remember which side your gas is on.
 
I'll get some pics up of the inner fender soon..I decided against the dual filler because they are known to cross contaminate and cost $$$.... Since I'm running a 2 tank wvo system I don't want wvo in my diesel tank...It was a tight fit mounting the filler and I did have to trim the corner of the plastic storage box to make room for the filler neck and hose..Also the passenger side was a good way to keep the tanks seperate so someone (wife, buddys) don't get confused as to which tank is which and the locking door just for extra measure....I will also have the ability to shut off all heat to the wvo system and run straight diesel in the second tank if I need to...
26gal sub + 25 stock = 51 gallons @ 25mpg =1275 miles till refuel:steer:
 
bhmmapping said:
I don't think toyota approves of cummins conversions either. People weld sliders on all the time.
Click to expand...

Okay let's go further, any engineer would say the same, this is not a pissing contest, is a safety issue.

I am game for bolt-on options against welding options.

You can weld a nut over a plate and insert this plate inside the framed box AS THE STOCK OEM hitch rear two bolts are holded in their place.

If people weld sliders is their problem and their risk but this is against what the boxed frame was designed.

Just look under your cruiser and you will notice how many rivets are used and how many weldings and welded nuts came on the frame from the assembling plant.:grinpimp:
 
Veggie80 said:
I'll get some pics up of the inner fender soon..I decided against the dual filler because they are known to cross contaminate and cost $$$.... Since I'm running a 2 tank wvo system I don't want wvo in my diesel tank...It was a tight fit mounting the filler and I did have to trim the corner of the plastic storage box to make room for the filler neck and hose..Also the passenger side was a good way to keep the tanks seperate so someone (wife, buddys) don't get confused as to which tank is which and the locking door just for extra measure....I will also have the ability to shut off all heat to the wvo system and run straight diesel in the second tank if I need to...
26gal sub + 25 stock = 51 gallons @ 25mpg =1275 miles till refuel:steer:
Click to expand...

Hijack, will the 4bt really get 25 mpg in the 80 series? If true, that is awesome!
 
You must log in or register to reply here.

Share this page

Back
Top Bottom