VFR Discussion Group -> Auxillary Fuel Cell Install on a VTEC

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Fuel Cell Installation on VFR

The Ironbutt Association allows up to 11.5 gallon of fuel (main+cell) and limits riders to 350 miles between fuel stops on certified rides. I decided to increase my fuel range after doing a few long distance rides. My goal was to get a 300 mile range so a 3-4 gallon cell on the VFR would do the job.

My first decision was to keep it simple and go with gravity feed. You run the main tank down to � tank and then open the cell valve. It takes 10-15 minutes for the cell to drain into the main tank. The down side of this setup is the higher center of gravity of the fuel compared to low mounted rear fender or saddlebag cells that requires an electric pump.

Main Tank Connection:

With a fuel injected bike, it�s easiest if you connect your fuel cell line to the main tank and stay away from the fuel delivery system. Carbed bikes you just �T� into the line between tank and carbs. You can install a standard bulkhead fitting (Sampson-Sporttouring has them) into the main tank. The risk being if you mess up, you have to get a new tank.

I went with installing a bulkhead fitting into the fuel pump plate (much cheaper part to replace). I saw this done on some Goldwing sites but the Viffer didn't have enough clearance for an off-the-shelf fitting. The only access point in the fuel pump plate was the area nearest the seat and clearance was tight under the main high pressure fuel line.

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Bulkhead fitting installed on fuel pump plate

I used a standard SST Swagelok bulkhead fitting and had it machined down to a 1/2" high profile and welded shut. A 1/4" hole was then drilled in the side of the hex at a 15 degree angle and a 1/4" tube to NPT adapter was welded in. I could then install my barbed hose fitting. I routed the fuel line under the seat to a shutoff valve that allows cell removal.

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Detailed view of custom fitting

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Fuel cell line routing

Fuel Cell Mount:

First generation:

I had a custom tail rack made of 1/4" thick Aluminum to mount the fuel cell. It attached to the grab rail mounts. Extra support was added by running brackets down to the reflector mounts on the OEM saddlebag brackets. I didn't get everything right the first time when it was welded so I ended up with bolted cross members and extra holes but this rack was rock solid.

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Tail rack attached to grab rail mount

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Support brackets

I ordered a 3 gallon polyethylene fuel cell on Ebay from a Florida race shop. It was the perfect size (8"x8"x14") to fit my tail rack. It was a simple rectangle so I made some thin Aluminum straps to secure it. JAZ, RCI, and Summit all make some nice cells of various 3-5 gallon sizes that are popular in the LD community.

Plastic cells require a wire to be attached to the fill neck for grounding. Vented caps are not allowed and overflow/venting must be controlled and directed away in a safe manner. I added a vent hose with standard bulkhead fitting to the top of my cell. The vent/overflow line runs down to the right passenger foot peg.

The final step was to paint the cell rack. The parts were sandblasted and I used self etching primer for bare Aluminum with a top coat of black semi-flat Krylon spray paint. Fuel valve to drop the cell fuel into the main tank is mounted on the left side and is easy to reach on the road. I strapped a cooler on the side to hold my water and power bars.

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Original mount

Second generation:

I found it took way too much time to install the fuel cell tail rack for rally�s and then take it off for normal riding. I also got way too much attention having that red tank hanging off the back. I wanted to run a Givi tail trunk for longer rides so I made plans over the winter to do a new mount over the back seat.

I ordered a Krauser K-Wing toprack from twistedthrottle.com. The new cell mounting base attaches to the front cross bar of the Krauser toprack with two bolts. The cell mounts clear the givi topcase base plate so cell installation is quick and easy. Mounting base was welded together from 1/4" thick Aluminum.

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New Fuel cell base plate

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Cell mounted and bolted to K-wing toprack

Brackets for the front of the cell mounting base were bent to fit between the rear cowl and saddlebags and bolt to the passenger peg bracket. A one-piece seat and the ability to remove it on the road (access battery & tools) required me to mount the cell higher than appears necessary at first glance. I use the space under the cell to store a small bag of gear.

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Front of Cell mount

Again - paint, attach ground wire, route vent line, mount cell valve on left side. The final step was to order a tank bag from Linda T. at CustomTankbags.com for my cell. I sent her pics with dimensions and 4 weeks later I got a bag that fit my cell perfectly. She integrated in an insulated water bottle holder on one side for on the road hydration.

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Custom Tank Bag

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View of bag and water bottle holder

The new cell mount and bag really worked out well for me. Installaton/Removal is now quick and easy.

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Final product (really)

Awesome! fing02.gif

Wow that's hardcore. Nice work. I spy an antenna. CB or UHF(GMRS/FRS)?

What is your communication system of choice?

Thanks.

That's pretty sweet man.

Great job & write up. I gotta find out...how did you mount your PIAA lights. I have a set ready to install & have not decided how I want to do it. But I was shooting for a mirror mount set up maybe.

Man!!! you are a pyromaniac! my last bike I had to stop and fill about every hundred miles, the VFR is so nice. You actually carry your own tanker, quite a set up fing02.gif

Awesome! beer.gif

Thanks for the writeup. I've been thinking about doing something very similar.

sick
nicely done

tharkun, Jun 6 2006, 09:32 PM...how did you mount your PIAA lights.

http://www.vfrdiscussion.com/forum/index.php?showtopic=20835

previous reply on my mirror mount.

Zyvek, Jun 6 2006, 08:38 PMWow that's hardcore. Nice work.  I spy an antenna. CB or UHF(GMRS/FRS)?

What is your communication system of choice?

I have a J&M CB for bike-to-bike communication because the group I do distance riding with all have CB. Not the strongest transmitter on the J&M, but it has amplified aux audio input for my satellite radio.

Great post, awesome mod, thanks for posting up!

I was hoping this would be more of a "bolt-on" operation, as much as I'd like to have a setup like this, there is no way could I pull something like this off.... bummer sad.gif

Great job nonetheless on your part...

moved to feature on the homepage

OK so with all that, what was the average gas mileage (in US gallons)?