Wednesday, April 1, 2020

Project Warthog: Getting Gas to Flow

With new fuel tank parts now in hand, we can continue the work on plumbing in the auxiliary fuel cell.

However while waiting for new tank parts, a discarded piece of aluminum diamond plate caught my eye,.... hmmm... odds and ends laying around and a cutter / grinder at hand makes for a dangerous situation.

Could not resist, made an elephant ear for the Warthog...? WHAT???   Now why would I do that??
Can you guess the purpose of the giant ear?

With new fuel tank parts in hand, now to figure out where to drill for the aux fuel line bulkhead fitting. After trying several different combinations and sizes, settle on this.

Note how bad the old plate was rusting and flaking. The tank itself is in great shape, no rust.

Dry fitted the 1/4" connection. Inside view. Can fit a socket or wrench on the nut to tighten.

Outside view of the barbed nipple with a rubber washer.

Started with the rubber washer but then remembering my experience with rubber and fuel in Canada causing leaking problems. Decided instead to go with JB Weld epoxy and a copper washer for a leak-proof stable seal.

Painted the epoxy in, under and between the inside fittings also.

Once the epoxy cured, added a length of fuel line with a quick disconnect fitting that extends past the edge of the main tank. Here it sticks out from under the tank.

Starting at the auxiliary fuel cell, first is a quick disconnect screwed into the tank,
 then the fuel line leading to...

...the inline fuel filter secured between the rear upper sidecar mount and the shock mount. Is not touching anything that might crack it. Wrapped the line clamps with electrical tape to cover sharp edges. Zip ties hold the line in place.

After experiencing getting bad gas on another ride, having an inline filter is very important. Plus having an easy way to clean or replace that filter without losing all of the fuel in the tank is critical.

Coming after the inline filter is the valve for turning the fuel flow on or off. This is a simple gravity feed flow, no need for a fuel pump. The Aux fuel cell sits higher than the main tank. Simplicity is best, easy to fix, can source replacement parts anywhere on the road. 

Oops, seems to be a gap between the shut off valve and the male quick disconnect fitting coming from the main tank.

Actually the gap is too small, as I need to fit a check valve and the female end of the quick disconnect in there.  Trimming back each of those two hoses should solve that.

The check valve allows fuel to flow to the main tank but does not allow fuel to flow the other way. 

That's where we are today. The Warthog project inches along each day, not all progress is dramatic or even visible. As long as I have the parts to work with, all is good. But the waiting for parts can get ugly, even produce elephant ears and all.

Oh, I can hear clearly now, the ra.........

The ear idea is to divert more air flow toward the exhaust headers on the right side of the engine. Have read of complaints from Rocket owners about the excess header heat burning holes in their rain gear. 

Next up is to mount the camper tub.

Stay tuned, riding weather is here. Am getting anxious to get the Warthog on the road.

Ride safe and far friends, cough in your elbow and wash your hands. 

Now... where can I mount a gallon bottle of sanitizer on the rig?



  1. Nice build photos. I was guessing the ear was to divert the wind but I couldn't figure out why.

  2. Good guess Richard, not sure it will work, but easily removed if not productive.

  3. Heck I thought you were using the "Elephant Ear" to act as leg guard like on the Urals.....

    This article reminds me I need to source and install quick disconnects for the fuel tank on my 2014 Ural....recent repair done emphasized this need and I'd forgotten since then, early onset of dementia, no doubt. Thanks.

    1. Caution if planning on using old quick disconnects with new ones. I discovered that some brand are not interchangeable. The fit was too loose and would leak fuel. Better to buy them in pairs - male and female. Beemer Boneyard had good prices on them the last I checked.

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