FrontRunner 45 gal aux tank install w/ pics

[AdventureBuddies]

I couldn't pass up the deal CampingLab had on the FrontRunner 45 gal tank so I bought one and will sell the 13 Gal OEM subtank. I did a straight swap, using the OEM dual filler neck. I know this is an obscure project but I'll post up some details in case anyone finds this in the search in the future.

My biggest goal was to keep the OEM sending unit but the FrontRunner doesn't come tapped for that (the LongRanger does) so I had to make arrangements for the sending unit.

I found an enourmous industrial washer at the specialty hardware store about 3" across and the perfect 1.75" inside diameter. I tapped holes for the OEM sending unit screws in the washer so that it would become the base plate for the sending unit to attach to since the tank walls are too thin to tap properly.

Next I had to determine where to mount the sending unit and how to modify the swingarm/float and low fuel sensor for the deeper tank. I mapped out the location of the baffles and support beams in the tank and extended the swingarm for the best range of motion where it won't snag on the internal supports.

To extend the swingarms, I cut the arm/wire and crimped on some stainless tubing as the extnsion and then crimped the end piece back on. A little JB weld (which is rated for gas tank repair) seals the ends of the tubing so the tube is bouyant. I was a little concerned that the float wouldn't be bouyant enough with the added weight of the longer arm. By making the arm extension bouyant it solves that potential problem. I bent and re-bent the extended arms until I was satisfied with the range of travel.

Then I cut a 1.75" hole in the tank in the chosen location, prepped the surface, and JB welded the tapped washer to the tank, careful to keep the epoxy out of the sending unit threads.

The tank mounts using some 3" square u-bolts over the frame cross brace toward the front. Those are easy to install once you get the tank into position. The tank is pretty heavy and getting it into position is a real pain. I placed the tank on a piece of plywood on a floorjack and raised and wrestled it into position. At the rear, you have to remove the bar that goes across the inside of the bumper frame - not sure what it does but I think it stabilizes the stock spare tire. The tank comes with brackets that attach to the holes from this stabilizer bar.

At first I was miffed because the brackets aren't drilled. But after test fitting I realized the wisdom in that. There are an infinite number of minute adjustment to fitting the tank and since each chassis is slightly different, the brackets are the easiest thing to drill for the best positioning so they each ended up at an odd angle but the tank is centered.

It's all mounted and tested and seems to work great. The tank took just under 45 gal which cost about $120 at the cheapest gas station in SoCal. I figure now I can make it from LA to SanFran and back without filling up. Good for our long term Africa travel goals.

Now the pics...

 

[AdventureBuddies]

more pics

more pics

 

[AdventureBuddies]

and the tank itself

picks of the tank

 

[AdventureBuddies]

the mounting

mounting brackets

 

[Michael Hanson]

Nice work. Mike

 

[80t0ylc]

Wow, that's a big tank! Looks pretty susceptible to damage and hangs pretty low. You planning on fabbing a skid plate for it? I'd recommend it. Don't get me wrong - I appreciate the beauty of an aux tank and have it in my long range plans. It peaks my interest immediately when I see a thread like yours. CampingLabs website said about $700 - was that what you paid and how much for shipping? I like the way you fabbed the sending unit! Keep us posted on it's performance.

 

[firetruck41]

How about a side profile pic, from about bumper height. It would give a good idea as to departure angle with the aux tank.

 

[elysium]

Looks pretty close. The Longranger (above) might hang down slightly less than the Frontrunner (below).

 

[Blueegg]

Nice tank and setup.

With 3 years of experience with a 34 gal tank, I echo 80t0ylc's thoughts about the need for a skid plate. Fear about running out of gas has been replaced with fear of tank damage.

It's easy to hit the tank on a rock and worries about damage to my tank limit where I go. Inspite of my concerns, I've got myself in situations ( following another 80 that has no problems) where there is no easy way out and banged the thing a couple of times.
Some kind of protection is on my must have list.

 

[SOCALFJ]

Right on, glad you got rid of the 13 gallon, seems like such a waste. Interesting u-bolt frame mount they did on this kit.

 

[Peluo]

I think the shipping is free from camping lab i paid almost 200 for the Man a fre 24 gallon one

 

[AdventureBuddies]

A skid plate is definately in the plans. I've conceptualized a few ideas. I want sometning that will bear a good amount of weight so it will brace on the chassis/bumper rather than just being an extra layer under the tank.

The design does hang lower than necessary. It could have been 3" wider on either side which means they could have made it 2" shallower with no loss of capacity. I was willing to sacrifce some trails since I've alreay taken this build fully in the expedition direction and away from the rock cralwing with other mods.

 

[SOCALFJ]

The design does hang lower than necessary. It could have been 3" wider on either side which means they could have made it 2" shallower with no loss of capacity. I was willing to sacrifce some trails since I've alreay taken this build fully in the expedition direction and away from the rock cralwing with other mods.

Don't sweat it.. you have built your rig the same way we have ours. Not for rockcrawling... if you were playing in the rocks you wouldn't need a sub tank at all. We love our 24 Long Range Auto.. even though it hangs down a little... but its worth the extra mileage... especially on our pig.

 

[80t0ylc]

A skid plate is definately in the plans. I've conceptualized a few ideas. I want sometning that will bear a good amount of weight so it will brace on the chassis/bumper rather than just being an extra layer under the tank.

The design does hang lower than necessary. It could have been 3" wider on either side which means they could have made it 2" shallower with no loss of capacity. I was willing to sacrifce some trails since I've alreay taken this build fully in the expedition direction and away from the rock cralwing with other mods.

I think you have a wise attitude towards the situation. Being as the tank is exposed to objects outside the wheelbase, you could contact an object backing up that escaped your notice and rip it open. Even an 'extra layer" might save the tank. If you're finding contact happening often, then pursue the frame mounting route.

Don't sweat it.. you have built your rig the same way we have ours. Not for rockcrawling... if you were playing in the rocks you wouldn't need a sub tank at all. We love our 24 Long Range Auto.. even though it hangs down a little... but its worth the extra mileage... especially on our pig.

I commend you on your expedition build, but at the same time I think , to disregard caution is to invite disaster. Even the stock tank, as tucked up as it is, has a feeble skid plate on it. The rear tanks are more exposed and IMHO in need of protection. You don't have to be rock crawling to get into a situation and damage the tank.

 

[SOCALFJ]

I commend you on your expedition build, but at the same time I think , to disregard caution is to invite disaster. Even the stock tank, as tucked up as it is, has a feeble skid plate on it. The rear tanks are more exposed and IMHO in need of protection. You don't have to be rock crawling to get into a situation and damage the tank.

Whats funny is that the stock tank sits lower than our aux tank. Stock at its lowest point sits 18.5" off the ground. The aux tank at its lowest point is 21" and our hitch that's integrated in our Kaymar is at 22".

Here's a shot of how high ours sits.. 2 years and i've never hit it once.. and we go out 1-2 times a month.


I'd like for someone with 33's and 3" of lift to measure they're spare if they have one back there.. i bet you our tank doesn't sit any lower.. and how often do you hit your spare?

 

[Atoyot1031]

I've got the Long Ranger protected by a Kaymar. I've put a few small dings in it, but yer not gonna "tear" it open.

I've got a video of a buddy in a Scrambler dropping off some pretty big rocks and landing on his custom tank (similar location). He dented it, but no big deal.

 

[Atoyot1031]

80tOylc, I think you've seen pics of mine in that thread about Kaymar rear bumper protection.

 

[MSGGrunt]

I just bought a Frontrunner from CampingLab. Couldn't resist the price, $700.00 with free shipping.

I want to run some sort of fuel sending unit and gauge, but not one out of an OEM sub tank or overhead unit. I was thinking about running a tube style sending unit with a corresponding correct gauge in the right Ohm range, 0 Ohms empty, 90 Ohms full.

The below sending unit is 11" deep. Where AdventureBuddies installed his OEM sub tank sending unit is 12.5" deep. Any thoughts? Does this sound like a sound way of installing a stand alone gas gauge for the auxilary tank?

Summit SUM-290181 - Summit® Fuel Sending Units – SummitRacing.com


Auto Meter 4314 - Auto Meter Ultra-Lite Analog Gauges – SummitRacing.com

 

[80t0ylc]

Whats funny is that the stock tank sits lower than our aux tank. Stock at its lowest point sits 18.5" off the ground. The aux tank at its lowest point is 21" and our hitch that's integrated in our Kaymar is at 22".

Here's a shot of how high ours sits.. 2 years and i've never hit it once.. and we go out 1-2 times a month.


I'd like for someone with 33's and 3" of lift to measure they're spare if they have one back there.. i bet you our tank doesn't sit any lower.. and how often do you hit your spare?

I'd say there's just a little bit of difference between your tanks clearance and AventureBuddies 45 gallon tanks clearance, wouldn't you? It might be worth some protection, dontcha think?

 

[80t0ylc]

I've got the Long Ranger protected by a Kaymar. I've put a few small dings in it, but yer not gonna "tear" it open.

IIRC, the Long Ranger is about half the capacity of the Frontrunner. All you have to do is hit the right rock or obstacle with momentum and your going to be slicing sheet metal. Going forward there's prolly slim to no chance 'cause you'd hang up before it reached your tank. But if you back into or onto this obstacle (don't forget your vision is quite handicapped in reverse) it's gonna get you.

I try to imagine the worst situations, so call me a pessimist. But for my money, whether it be Long Ranger or Frontrunner, when I get around to my aux, it's going to have (minimum) at least the stock tank type of protection.

I've got a video of a buddy in a Scrambler dropping off some pretty big rocks and landing on his custom tank (similar location). He dented it, but no big deal.

Years ago I had Arrow Tanks, then in Placentia, CA, build me a 50 gallon tank for my '79 Chev. Luv 4x4. It sraddled the drive shaft & I modified the exhaust. I had my brother in law fab me a skid plate that well protected it from rocks. However, I came down on it several times and ended up getting a slow leak near one of the mounts since the skid plate was attached to the mounting hardware for the tank. You just can't be too careful. I loved pulling into a gas station with that (13 gallon stock tank) mini truck and watch the attendants lose their minds as the pump dinged on past 30 gallons, 40 gallons, etc!