How to Make an Extended Fuel Tank for Generator: The Ultimate DIY Guide

Tired of constantly refilling your generator’s fuel tank? Want to enjoy uninterrupted power during outages or extended outdoor events? Building an extended fuel tank for your generator is a practical and cost-effective solution. This guide will walk you through the process, from choosing the right materials to safely connecting your new tank.

Why Build an Extended Fuel Tank?

Generators are invaluable during power outages, but their limited fuel capacity can be a major drawback. An extended fuel tank offers numerous advantages:

• Extended Run Time: Enjoy hours of uninterrupted power without frequent refueling.
• Increased Convenience: Say goodbye to constant trips to the gas station.
• Cost Savings: Reduce fuel consumption by using a larger tank, potentially saving money in the long run.
• Peace of Mind: Knowing you have a reliable power source for extended periods provides peace of mind during emergencies.

Choosing the Right Materials

Before you start building, gather the necessary materials:

• Fuel Tank: Choose a tank made from durable and safe materials like polyethylene or stainless steel. Consider the size you need based on your generator’s fuel consumption and desired run time.
• Fuel Line: Select a fuel line specifically designed for gasoline or diesel, depending on your generator’s fuel type. Ensure it’s the correct diameter and length.
• Fuel Filter: Install a fuel filter to prevent debris from entering the generator’s engine.
• Fuel Pump (Optional): If your generator doesn’t have a built-in fuel pump, you’ll need an external one to transfer fuel from the extended tank.
• Hose Clamps: Securely connect the fuel line to the tank and generator using hose clamps.
• Valves (Optional): Consider adding valves to control fuel flow and isolate the extended tank when not in use.
• Brackets and Mounting Hardware: Securely mount the extended fuel tank to your generator or a nearby surface.

Safety First: Essential Precautions

Building an extended fuel tank involves working with flammable materials, so safety is paramount:

• Work in a Well-Ventilated Area: Avoid working in enclosed spaces to prevent the buildup of flammable vapors.
• No Smoking: Strictly prohibit smoking in the work area.
• Use Proper Tools and Equipment: Handle tools and equipment carefully to avoid sparks or accidental spills.
• Wear Protective Gear: Protect yourself with gloves, safety glasses, and appropriate clothing.
• Store Fuel Safely: Always store fuel in approved containers away from heat and ignition sources.

Step-by-Step Guide to Building an Extended Fuel Tank

Now, let’s dive into the step-by-step process of building your extended fuel tank:

1. Prepare the Fuel Tank: Clean the tank thoroughly to remove any debris or contaminants. If necessary, use a degreaser to remove any residual oils or grease.
2. Install the Fuel Line: Cut the fuel line to the appropriate length and attach it to the tank using hose clamps. Ensure the connection is secure and leak-free.
3. Connect the Fuel Filter: Install the fuel filter in the fuel line, ensuring the arrow on the filter indicates the correct flow direction. Secure the filter with hose clamps.
4. Connect to the Generator: Attach the other end of the fuel line to the generator’s fuel inlet. Use hose clamps to secure the connection.
5. Install the Fuel Pump (If Necessary): If you’re using an external fuel pump, connect it to the fuel line between the tank and the generator. Follow the manufacturer’s instructions for installation and wiring.
6. Mount the Fuel Tank: Use brackets and mounting hardware to secure the fuel tank to your generator or a nearby surface. Ensure the tank is stable and properly supported.
7. Test for Leaks: Before using the extended tank, thoroughly check all connections for leaks. Tighten any loose connections and address any leaks immediately.

Using Your Extended Fuel Tank

Once you’ve successfully built and tested your extended fuel tank, you can start using it:

• Fill the Tank: Carefully fill the extended fuel tank with the appropriate type of fuel for your generator. Avoid overfilling the tank to prevent spills.
• Turn on the Generator: Start your generator and ensure the fuel is flowing properly from the extended tank.
• Monitor Fuel Levels: Check the fuel level in the extended tank periodically to ensure you have enough fuel for your needs.

Maintaining Your Extended Fuel Tank

Regular maintenance is crucial for ensuring the longevity and safety of your extended fuel tank:

• Inspect Connections: Periodically check all connections for leaks or loose fittings. Tighten any loose connections and address any leaks promptly.
• Clean the Fuel Filter: Replace the fuel filter according to the manufacturer’s recommendations or as needed. A dirty filter can restrict fuel flow and affect engine performance.
• Inspect the Fuel Tank: Visually inspect the fuel tank for any signs of damage or corrosion. Repair or replace damaged tanks immediately.
• Store Fuel Properly: When not in use, store fuel in approved containers away from heat and ignition sources.

Final Thoughts: Power Up Your Generator with an Extended Fuel Tank

Building an extended fuel tank for your generator is a practical and rewarding DIY project. By following these steps and prioritizing safety, you can enjoy the benefits of extended run time, increased convenience, and peace of mind during power outages or outdoor events. Remember, regular maintenance is essential for ensuring the longevity and safety of your extended fuel tank.

Answers to Your Most Common Questions

Q: What size fuel tank should I use?

A: The size of the fuel tank depends on your generator’s fuel consumption and desired run time. Consider how long you need the generator to run and calculate the amount of fuel required.

Q: Can I use any type of fuel tank?

A: It’s crucial to use a fuel tank specifically designed for gasoline or diesel, depending on your generator’s fuel type. Avoid using tanks intended for other liquids.

Q: How do I prevent leaks?

A: Use high-quality fuel lines, hose clamps, and fuel filters. Thoroughly inspect all connections for leaks before using the extended tank.

Q: What are the safety precautions I should take?

A: Work in a well-ventilated area, avoid smoking, use proper tools and equipment, wear protective gear, and store fuel safely.

Q: How often should I maintain my extended fuel tank?

A: Inspect connections, clean the fuel filter, and visually inspect the tank regularly. Follow the manufacturer’s recommendations for filter replacement.