Hellivue Aux Tank

[BigNick]

The GX has a Metal Tech Pegasus Rear Swing Out Bumper. This is the Hellivue18g aux tank, theres another install thread thats pretty thorough. What has suprised me so far about this install is the amount of clearancing and how many pieces are back there to accomadate the spare. It all has to come out, starting with the spare tire xmember. I like everything about this tank, theres alot to do to get it up in there right up front, be ready. But, once its in, it fits up in there really good. It looks like it shouldnt see any rocks, but, one never knows until its battle tested.

BTW, if you look at the left side of the tank in the pic, which is actually the back of the tank, you can see 2 sets of scratches. These are whats left after me fitting it into the space and not clearancing the trim brackets. I do have my bumper trim positioned downward with nylon spacers to accomadate the bumpers positioning and the brackets for the bumpers trim. So this could be why Im experiencing clearance issues there.

Parts and hardware bags

Everything that has anything to do with that spare mount has to be clearanced with a cutter.

Driver side, while Im here Im pulling the air pump, lines and as much harness I can safely do. I also have to figure out another location for the 7 pin trailer connector. The tank takes up every bit of space between the frame rails and all the way back. I'm thinking it will go outside the frame rail up in, after the pump is removed. I'll carry an extension for the times I want to tow.

BTW, on the tank in the backgound, the fill nipple on top and the drain on the bottom, both covered with blue tape.

Pax side, theres also an M8 insert in the very back of the image for the right rear mount.

Reroute and secure the wire harness. Plus you can see where I clearanced back on the rear frame xmember. Theres 2 pieces back there, spare tire bracket pressure guides that have to come out and I dont have a pic, but the tool guide for the crank pole has to be clearanced, i.e. cut away.

 

[BigNick]

More rerouting and securing the harness, I like those adel clamps, I put an old one in there that was on my jeep years ago, I should probably pull it and put a new one. You can see the M8 insert for the left side front tank mount.

Reposition the canister filter with the extension strap that comes in with the kit and the hardware. This is so it doesnt interfere with the top tank fill nipple.

These brackets I clearanced a little but it wasnt enough, they still touch the tank, I have to grind the side reinforcements down, additionally, I'll shim the tank a little when I install. You can see the M8 insert and I repositioned the ground wire.

Driver side

Pax side, the M8 insert is there too.

Heres the bumper itself, its really pretty much not a conflict with the tank.

This is as far as I got with it today. Im going out of town for a few days so odds are, I'll get back on it when I get back.

 

[Rednexus]

Looks like a nice setup and is reasonably priced (for a long-range tank anyway. Curious to see how it performs!

 

[BigNick]

Pulled the air pump out this morning, dead weight, takes up space, does nothing. This frees up space outside the frame rail for the 7 pin trailer plug. Amazing how Lexus fits 10lbs of stuff in a 5lb bag.

 

[BigNick]

Looks like a nice setup and is reasonably priced (for a long-range tank anyway. Curious to see how it performs!

Well Red, a couple 5 gallon cans would be alot cheaper and easier to install, but I've never been one to take the easy, less expensive route. They had a sale on them so I picked one up. Especially since my last overland run where I needed 5 gallons of fuel to get back to the road, someone had cans so I got some. With this, that shouldn't happen again.

 

[Jstawgn]

Pulled the air pump out this morning, dead weight, takes up space, does nothing. This frees up space outside the frame rail for the 7 pin trailer plug. Amazing how Lexus fits 10lbs of stuff in a 5lb bag.

I am trying to remove lots of old entertainment system too. It's unbelievable how heavy and complex is navigation and rear seat entertainment crammed to this car. Even rear backup camera got its own ECU and many wires. The navigation ECU below passenger seats are otner useless one if you already convert to newer headubit.

Been almost 2 years since I install my first Gen Hellivue tank. It's a welcomed upgrade. Makes a lot less range anxiety during remote travel.

 

[BigNick]

The air system harness. Where to stow it.. Im thinking on top the spring tower.

 

[Rednexus]

I taped up all of the connectors on mine and then zip tied the harness to the top of the crossmember it's dangling from.

 

[BigNick]

Double wrap ziplocs, tie wraps. Considering a nice wrap of duct tape?

 

[Rednexus]

I used electrical tape on mine, but wrapped each connector with probably 10+ layers of tape. The ziploc could puncture and hold water, which would not be good.

 

[BigNick]

Yeaaa, Im thinking on that Red. Im not satisfied with that kind of stow. This is why projects take me so long, I consider, for awhile, the possibilities. I think it will do the trick but aestetically, Im not liking how it looks.

 

[BigNick]

A nice wrap of duct tape and seems it'll ride good right there. The question with this I failed mention earlier is, the fuel fill line has to come out for mods so I've been trying to keep it as far away from it as possible but, there's really no choice. That harness is running right over the top of that fill line. The fuel fill is visible there with the zip ties on it from the diff breather mod I did way back when.

Trim the brackets and paint to make room for the tank:

These are the brackets that this bumper trim attaches:

 

[BigNick]

I always love these conundrums. The image from the instructions clearly shows 3 lines on the top of the tank, rollover, fast fill and transfer. My tank from Hellivue has one fitting. Hmm.. I'm thinking this stops me for the weekend until I can make a phone call to sort it out. Any thoughts from the brain trust of IH8Mud ?

Edit: I cant believe I didn't catch this mess until now. The other modification thread here is the 3 line set up too.
One of the things I'll say, the instructions have always been lacking. My tank didnt come with a set, I called or wrote and they emailed them. Which I two sided printed all 21 pages in color, then ran a staple in there. Now,, it looks like those instructions are for an earlier generation tank. Good point is they answer their phone, so Ill give them that. And, what they're producing is really nice. And, I think they're in the Valley of The Sun, an area close to my heart as I lived there for a dozen years.

 

[BigNick]

Trying to sort it out on my own. I believe the top fitting to be vent. Not sure where the other end of the hose goes. The top right corner is fast fill, it ties into the hard fill line on the GX. I dont believe the larger longer piece of hose here is long enough. The bottom right bung is the transfer out. It seems the AN fitting they sent is the wrong size for the bung welded to the tank, too big. Anyways, its hose leads to the fuel filter, the pump and then to the transfer nipple on the fast fill adapter which goes in the hard fill line.

I sent Hellivue Designs an email questioning these issues. We'll see what they say. At any rate the GX is drivable so this project on hold until it gets sorted out.

So far clearancing and mounting has been quite a task. Now on to plumbing of which the instructions are for an older version and the fittings are incorrect.

The last bit is going to be electrical and wait till you see that. I have a feeling chaos will be involved at some point. Such is the case with major mods like this. We are presented with incorrect, insufficient parts and information. Yet we press on and overcome the obstacles striving for the builds we have envisioned.

 

[BigNick]

This is the area cleaned out and completely clearanced, wire harnesses routed and secured, ready for the tank to go up. Im thinking I'll have extra time now so ill get up in here with a hose, a bucket of soapy water and a scrub brush and clean it up before the tank goes up.

 

[BigNick]

While posting here I also emailed Hellivue. I recieved an email back from the owner operator apologizing for the instructions mix up. He sent me the correct set with the email. He also offered some guidance on the pieces I have which as it turns out, are all correct. The NPT fitting did not fit because of a slight deformity of the bung from one time when it fell off the floor jack. I was able to get the fitting in and tightened. I attached the vent hose and fitting to the top and carefully raised the tank into position with the floor jack. I was able to get the mount bolts in and secure the tank in place. Pictures tomorrow in daylight. This tank fits in there like a glove and seems to be well up out of the way. I will move on to the plumbing tomorrow. The main tank hard fill line will come out and get modded. That should be fun.

I must admit, customer service with these guys is above and beyond.

 

[BigNick]

Tank? What tank?

Here it is..

Fits like a glove gentlemen.

 

[BigNick]

Pull the wheel off and remove the wheel well liner. Good luck with the clips, they are Toyotas best ball buster clips, some in the worst possible locations. Toyota Pn # NF8-1. The extra hose there is the diff breather mod.

Next up, temp install the "T" fitting and figure where to cut the hardline. Then the hardline comes out.

 

[BigNick]

Doing the mock up on the fast fill T fitting to find where the OEM hard line gets cut. Looks like the supplied hose has come up 2" short, so I'll be heading to the parts store for a longer piece of fuel resistant 1" line. Tomorrow..... Today, besides this mock up, I got under there with a power washer and cleaned the area up. Overflowing the fuel fill over the last 18 years has left some fuel residue. It was too hot to be out there during the heat of the day.

 

[BigNick]

Got the fill line out. They build the car around the thing but no fear, just got to wrenching and cutting. I had to cut the line in half while still up in there. This is because with the aux tank installed, theres no room to turn the fill line in position to snake it out. I decided I didnt want to drop it out for this cut. The fill line was disconnected from the main tank (which took some friendly persuasion) but I got it. It just pulls straight off, no tricks. It was stuck on there but I stayed on it and got it. I capped the main tank and positioned the fill line for cutting while measuring and eyeballing many times. I cut the main fill line with a reciprocating saw after using a giant C clamp to secure it to the frame while I cut. I got it cut and snaked it out. Lots of metal shavings, I had covered all the lines so none of that stuff found its way in. On the bench, I measured time and again to make sure, then I further cut the line to accept the T fitting. I will say this, if your going to do this mod, make sure your comfortable with tools and cutting and grinding on your rig. Lots of that going on here. Time to take it to the welder to get the vent hose bung welded on.

Aside from all this, Hellivue owner operator is sending me the correct length fill hose, 8" vs 6".