Jcris Posted October 16, 2018 Share Posted October 16, 2018 At long last the new gas tank is installed and working properly. I removed the existing side mount tank and filler, both fuel pumps and the fuel lines from the black plastic canister type filter all the way back to the new tank. The only real issues that surfaced were: The black plastic filter turned out to be clogged and the new high pressure pump (located on the frame rail) seems excessively noisy. But the truck has been starting consistently since the work was completed a couple months ago, so I'm leaving it alone until I get a chance to take a closer look. This wasn't a really tough job but did take some thinking, which seems a real struggle sometimes. haha I'm only posting in case someone has specific questions that I may be able to help with. Thanks for a great forum, Jcris Link to comment Share on other sites More sharing options...
Gary Lewis Posted October 16, 2018 Share Posted October 16, 2018 Excellent! I have a question: I'm assuming you modified the in-tank pump & pickup by extending them down. Right? How well did that go? And does it seem like the fuel gauge is tracking to the bottomish of the tank? Did you do anything to ensure that, like sight through the filler hole to see how far the float drops and keep doing that until it hit bottom? And, does the pickup seem to get essentially all of the fuel? Again, did you do something to ensure that is the case? Last, apparently you are happy with 38 gallons, total, of fuel. Right? Link to comment Share on other sites More sharing options...
Jcris Posted October 18, 2018 Author Share Posted October 18, 2018 Excellent! I have a question: I'm assuming you modified the in-tank pump & pickup by extending them down. Right? How well did that go? And does it seem like the fuel gauge is tracking to the bottomish of the tank? Did you do anything to ensure that, like sight through the filler hole to see how far the float drops and keep doing that until it hit bottom? And, does the pickup seem to get essentially all of the fuel? Again, did you do something to ensure that is the case? Last, apparently you are happy with 38 gallons, total, of fuel. Right? Modifying the pump seemed fairly straight forward . When the tank was purchased we bought a kit to extend the pump and pickup. The kit was minimal as it only had some tubing and wire. I choose to use some fuel hose to make the connections to extend both pipes. And some worm drive clamps. I was going to use some compression fittings but after seeing the way the stock pump was attached with fuel hose I figured that would be easier. At first I just used an extended piece of fuel hose to determine what actual length of hard tubing to use. I did sight through the filler port with a mirror to "see" where everything ended up. After some trial and error I was able to get it pretty close. I did use some good quality butt connectors to extend the pump wiring. I wanted to just solder/and shrink wrap them but was uncertain how the fuel would affect the solder over time. That is one thing I may change when I get in there. I'm not a big fan of butt connectors, especially if the crimping tool is less than ideal. As for the fuel gauge, it does seem to track pretty well although it only shows an accurate level from half a tank to empty. With a full tank it still only shows half full. I considered installing a reed type switch to get a more accurate reading from full to empty but we decided just to use it as is for now. I will say when the gauge shows empty it is very close to empty. E means empty, no reserve. So it's getting all the fuel. As to the 38 gallon tank it seems like that should have been a stock offering back in the day. As opposed to the 2 separate tanks. That 2 tank system probably worked fine when new but down the road that set-up seemed to cause problems. Just my opinion there. Are you planning a tank install? I wish I'd taken some pics of the work to post here, As you may recall this is my brother in laws truck and they live several hours away. Otherwise I'd take some pics to be more clear. Next time I'm in town I will send some along. If any other questions should occur to you just let me know and I will be glad to help. I'm certainly no expert, far from it, but I've made this change and it seems to be working quite well. So, perhaps my knowledge has improved just a little bit. HaHa Probably won't be able to post on this again for a few weeks. I'll send some pics then Till then, take good care, Jcris Link to comment Share on other sites More sharing options...
Gary Lewis Posted October 18, 2018 Share Posted October 18, 2018 Modifying the pump seemed fairly straight forward . When the tank was purchased we bought a kit to extend the pump and pickup. The kit was minimal as it only had some tubing and wire. I choose to use some fuel hose to make the connections to extend both pipes. And some worm drive clamps. I was going to use some compression fittings but after seeing the way the stock pump was attached with fuel hose I figured that would be easier. At first I just used an extended piece of fuel hose to determine what actual length of hard tubing to use. I did sight through the filler port with a mirror to "see" where everything ended up. After some trial and error I was able to get it pretty close. I did use some good quality butt connectors to extend the pump wiring. I wanted to just solder/and shrink wrap them but was uncertain how the fuel would affect the solder over time. That is one thing I may change when I get in there. I'm not a big fan of butt connectors, especially if the crimping tool is less than ideal. As for the fuel gauge, it does seem to track pretty well although it only shows an accurate level from half a tank to empty. With a full tank it still only shows half full. I considered installing a reed type switch to get a more accurate reading from full to empty but we decided just to use it as is for now. I will say when the gauge shows empty it is very close to empty. E means empty, no reserve. So it's getting all the fuel. As to the 38 gallon tank it seems like that should have been a stock offering back in the day. As opposed to the 2 separate tanks. That 2 tank system probably worked fine when new but down the road that set-up seemed to cause problems. Just my opinion there. Are you planning a tank install? I wish I'd taken some pics of the work to post here, As you may recall this is my brother in laws truck and they live several hours away. Otherwise I'd take some pics to be more clear. Next time I'm in town I will send some along. If any other questions should occur to you just let me know and I will be glad to help. I'm certainly no expert, far from it, but I've made this change and it seems to be working quite well. So, perhaps my knowledge has improved just a little bit. HaHa Probably won't be able to post on this again for a few weeks. I'll send some pics then Till then, take good care, Jcris I am planning a 38 gallon tank install on Big Blue. But I have intended to keep the front tank since going off-roading or overlanding can require a lot of fuel and having the reserve is good. Especially if there's a chance of puncturing a tank. However, I'm going with the later model pump/sending unit combo that doesn't require a switching valve since those things are frequently a source of trouble. Anyway, which sending unit did you use? I can see that using one from a 19 gallon tank wouldn't have the range for the 38 gallon tank. But I would have thought one for a 32 gallon Bronco tank would come pretty close. Link to comment Share on other sites More sharing options...
kramttocs Posted May 10, 2019 Share Posted May 10, 2019 I am planning a 38 gallon tank install on Big Blue. But I have intended to keep the front tank since going off-roading or overlanding can require a lot of fuel and having the reserve is good. Especially if there's a chance of puncturing a tank. However, I'm going with the later model pump/sending unit combo that doesn't require a switching valve since those things are frequently a source of trouble. Anyway, which sending unit did you use? I can see that using one from a 19 gallon tank wouldn't have the range for the 38 gallon tank. But I would have thought one for a 32 gallon Bronco tank would come pretty close. Interested in knowing the details/gotchas around this install also. This is F26D, correct? The one that works with the intank pump (86 460)? Started watching a few videos and reading some forum posts on it last night. It sounds like the F26D comes with everything needed to extend the pickup/pump/float. Is that correct? Good photos here: http://www.northtexaspowerstrokes.com/mods/38gallontank/ although I am not keen on buying a $100+ sending unit just to swap out the float. Link to comment Share on other sites More sharing options...
Jcris Posted May 10, 2019 Author Share Posted May 10, 2019 Interested in knowing the details/gotchas around this install also. This is F26D, correct? The one that works with the intank pump (86 460)? Started watching a few videos and reading some forum posts on it last night. It sounds like the F26D comes with everything needed to extend the pickup/pump/float. Is that correct? Good photos here: http://www.northtexaspowerstrokes.com/mods/38gallontank/ although I am not keen on buying a $100+ sending unit just to swap out the float. If you’re running just one fuel tank take the switching valve and filter housing out completely. The valves in that housing rust and can stop flow completely. Took me awhile to get that figured out Good luck Link to comment Share on other sites More sharing options...
kramttocs Posted May 10, 2019 Share Posted May 10, 2019 If you’re running just one fuel tank take the switching valve and filter housing out completely. The valves in that housing rust and can stop flow completely. Took me awhile to get that figured out Good luck Thanks. I am actually wanting to keep both tanks as everything is working as expected currently. Was just going to increase capacity if it was easy enough to get an end result where everything worked as if it was stock. Link to comment Share on other sites More sharing options...
Jcris Posted May 10, 2019 Author Share Posted May 10, 2019 Thanks. I am actually wanting to keep both tanks as everything is working as expected currently. Was just going to increase capacity if it was easy enough to get an end result where everything worked as if it was stock. Yeah that’s cool You know how this stuff usually goes. It takes more time than you expect and there are pitfalls to overcome. This forum is a good one though, kinda small but some really good guys helping out. Is your rig setup with 2 tanks now? I ask because I’m unsure how the additional pump would be added. Probably be easier if you can use all plumbing and electrical from the 2nd tank. Just curious Also, getting the pump in tank height set is a bit tricky, kinda trial and error Good luck  Sent from my iPhone On May 10, 2019, at 6:51 AM, kramttocs [via Bullnose Enthusiasts] <redacted_email_address> wrote:  Thanks. I am actually wanting to keep both tanks as everything is working as expected currently. Was just going to increase capacity if it was easy enough to get an end result where everything worked as if it was stock.Daily driver: 1986 F250 Supercab XLT Lariat 460/C6Work truck: 1980 F350 C&C 400/T18 - Gin PoleVarious parts trucks   If you reply to this email, your message will be added to the discussion below:http://forum.garysgaragemahal.com/38-gallon-fuel-tank-install-tp16115p27639.htmlTo unsubscribe from 38 gallon fuel tank install, click here.NAML    Link to comment Share on other sites More sharing options...
kramttocs Posted May 10, 2019 Share Posted May 10, 2019 Yeah, two tanks currently with the switch and all that working. Just wanting to get a few more miles between fill ups :) Have the bed off now and going to be removing the 19gallon rear tank to paint the frame so figured now would be the ideal time to do the swap. May just save it for a later date though. Too many irons in the fire and all that. Link to comment Share on other sites More sharing options...
Gary Lewis Posted May 10, 2019 Share Posted May 10, 2019 Interested in knowing the details/gotchas around this install also. This is F26D, correct? The one that works with the intank pump (86 460)? Started watching a few videos and reading some forum posts on it last night. It sounds like the F26D comes with everything needed to extend the pickup/pump/float. Is that correct? Good photos here: http://www.northtexaspowerstrokes.com/mods/38gallontank/ although I am not keen on buying a $100+ sending unit just to swap out the float. As I said, I haven't done the installation of that kit, but I have it and it does look complete. As for the in-tank pump, the tank has the large opening so can accommodate that pump. But, there were sending units that fit that tank and don't have a pump with them. I'm just about to launch into the transformation of Big Blue to EFI, and in doing so I'll be using that tank and will write up what I find. And, while I am planning on keeping the mid-ship tank as well, I'll be using the later fuel delivery modules in the tank, which have the sending unit, pump, and valves. So mine will be different than yours. Link to comment Share on other sites More sharing options...
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