expanding the range of a 99 sport, second fuel tank?

[JB3]

Looking for input on getting more than 250 miles out of my 99 sport. I am using it for a survey job which has a lot of driving. The explorer excels at the job except for two things, economy and range. The fuel economy, while poor, can be acceptable if i could up the range a bit. As it stands i fill up this truck every single day i use it for this job, and have almost run out of fuel dozens of time now.

What i would like to do is mount another fuel tank where the spare tire is, and add a fill port through the floor or behind the bumper.

Then i was considering 3 ways to plumb it.

A- add a second fuel pump and switching valve and gauge, and a switch that shuts off one pump and kicks on the other between tanks.

B- get a different same spec external fuel pump and mount it outside the tanks, then do a switching valve downstream between tanks. The upside here is no loss of pressure issue when switching and possible check engine lights.

Or 3, leave things in stock configuration and add a transfer pump and a switch to pump fuel from the rear tank to the front tank when it gets low.

As for tanks i was thinking of buying a bronco 2 tank and seeing if it fits and building brackets.
What do people think? So far im leaning towards B if i can find the correct external pump

 

[SupaSwope]

I have thought about doing this for a while now. But in all honesty number 3 looks like the easiest option to do. (I think)

 

[LoquetusofBorg]

Or option 5, which is what my plan is. I believe Aldive did this also.
http://newhorizonshydrogengenerators.com/about/products/
Aldive built his own and had success with it, he also did a few other things to get his explorer 32 mpg. There is also a write up here on adding a 22 gallon fuel cell from a ford e-250 as that tank fits between the rear frame rails, his write up has lots of pictures- a lot of work. Good luck!
Robert

 

[JB3]

Or option 5, which is what my plan is. I believe Aldive did this also.
http://newhorizonshydrogengenerators.com/about/products/
Aldive built his own and had success with it, he also did a few other things to get his explorer 32 mpg. There is also a write up here on adding a 22 gallon fuel cell from a ford e-250 as that tank fits between the rear frame rails, his write up has lots of pictures- a lot of work. Good luck!
Robert

thanks for that link, I did find that thread on the Van fuel tank! great info

http://www.explorerforum.com/forums/index.php?threads/want-to-relocate-your-gas-tank.249316/

I wonder if I can do something similar for my gen 2

 

[JB3]

I have thought about doing this for a while now. But in all honesty number 3 looks like the easiest option to do. (I think)

Upon consideration thats the way I might go instead. I had forgotten that 99 was the change year to a returnless fuel system which would hugely complicate mucking with fuel delivery. Also there is an argument to be made for not playing with the stock system for emergency repair on the road by a shop unfamiliar with anything I might have done.

learned that lesson the hard way once already on a van I once repowered

 

[LoquetusofBorg]

yup! you can do anything, well most anything providing your pockets are deep enough.
Robert

 

[boominXplorer]

2wd or 4x4? If its 2wd I bet a 4dr tank would fit. That would give you an added 5 gallons

 

[koda2000]

IDK

2wd or 4x4? If its 2wd I bet a 4dr tank would fit. That would give you an added 5 gallons

IDK about that. Maybe, but the 4 door has a longer wheelbase than the 2 door and the extra tank length would have to go to the rear because of the way the tank mounts. There's not much in the way of extra room to the rear.

 

[chefduane]

What about just carrying some good-sealed jerry cans? Not the most elegantly engineered solution, but it might solve the problem in the short run.
... just a thought.

Reminds me of an anecdote: In the '80's there was an international space exploration symposium and each nation was presenting how they solved writing issues in a zero-gravity environment. The Japanese presented their internally pressurized ink feed pens, the Chinese used indelible felt tips with non-evaporation ink, we Americans described how we spent $50mil developing our 'space pen.' The Russians walked to the podium and held up a pencil made by the Ticonderoga Pencil Company of Heathrow, Florida.

 

[RangerX]

I'm with chefduane, get a couple jerry cans and a rear bumper mount. So much cheaper and easier.
I do get the whole second tank thing, though. When I had an older F250, flipping the switch to the second tank was a kick and a lifesaver!

 

[boominXplorer]

IDK


IDK about that. Maybe, but the 4 door has a longer wheelbase than the 2 door and the extra tank length would have to go to the rear because of the way the tank mounts. There's not much in the way of extra room to the rear.

The tank length difference is in the front. Same concept of putting a sport tank in a 4dr so you can do an electronic 4406 swap and have room for the shift motor. Then its all factory hook up as long as its 2wd.

 

[JB3]

I like the jerry can idea but i dont like the idea of having a full gas can on the rear of the truck or in the cabin if im in the cabin all day.

I use this in a 100 square mile territory that includes two major metropolitan centers and being rear ended is a major concern, plus jerry cans might interfere with my lighting hazard signage.