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View Full Version : Auxilliary Fuel Cell Installation on a Buell Ulysses


2Evil4U
03-19-2008, 10:35 PM
Well, I started the install of my 4-gallon fuel cell this evening. I went as far as I could until I get the two additional fittings I ordered. They should be in Friday and I should have this completed by Sunday.

My two goals with this installation are to keep all of the functionality of the rest of the accessories on the bike and to have the cell and the stock tank act as a single tank that drains automatically without any manual valves or pumps.

Here is the pile of parts.

http://img.photobucket.com/albums/v121/2evil4u/CIMG1847.jpg

The location with the Triple Tail in the lowered position like I usually keep it.

http://img.photobucket.com/albums/v121/2evil4u/CIMG1848.jpg

A few pictures of my first mock-up as I was trying to figure out how to attach the cell.

http://img.photobucket.com/albums/v121/2evil4u/CIMG1849.jpg

http://img.photobucket.com/albums/v121/2evil4u/CIMG1850.jpg

http://img.photobucket.com/albums/v121/2evil4u/CIMG1851.jpg

A quick trip to the hardware store for some bolts and spacers and the cell is attached to the triple tail.

http://img.photobucket.com/albums/v121/2evil4u/CIMG1852.jpg

Shot after plumbing the oem tank vent and the cell vent.

http://img.photobucket.com/albums/v121/2evil4u/CIMG1853.jpg

How can I get the seat off you ask?

http://img.photobucket.com/albums/v121/2evil4u/CIMG1854.jpg

Thusly:

http://img.photobucket.com/albums/v121/2evil4u/CIMG1855.jpg

http://img.photobucket.com/albums/v121/2evil4u/CIMG1857.jpg

Trunk still opens plenty wide:

http://img.photobucket.com/albums/v121/2evil4u/CIMG1859.jpg

http://img.photobucket.com/albums/v121/2evil4u/CIMG1858.jpg

And a shot after a quick test ride:

http://img.photobucket.com/albums/v121/2evil4u/CIMG1860.jpg

I need another 8AN swivel 90 for the fuel feed line and an 8AN cap for the other cell vent. Then I can finish the plumbing.

My only concern at this point is if the cell will drain properly as the tank vent line runs lower than the top of the tank, even though it connects to the cell at the same level as the fuel feed. The feed line will be run into the drain plug at the lowest portion of the tank so it should have the best shot at working correctly.

More news as it develops.
I_FLY_LOW
03-19-2008, 11:01 PM
Neat install Evil!
Swampy
03-19-2008, 11:02 PM
Thats pretty cool.. How much fuel will you have total now?
2Evil4U
03-19-2008, 11:15 PM
Thanks! This will bring the total on board to right about 8.4 gallons. At 75 MPH that should put me in the 350-375 range before the idiot light comes on. (Assuming I can get it to drain into the main tank properly.)
scooterhose
03-19-2008, 11:43 PM
Cool12 Nice step by step.
Swampy
03-19-2008, 11:47 PM
Thats awesome... I have to stop after about 230 or so.. I dont think I could sit in the saddle for 300 anyway..:respect:
jason70360
03-20-2008, 04:05 PM
Damn Aaron! Do you think the extra weight will make it feel top heavy?

Well next time we ride I will count how many times the front stays down. Not like the big Buell motor needs any help lifting the front though.
Ritten
03-20-2008, 04:47 PM
Looking good Aaron!!!
Juice
03-20-2008, 04:59 PM
Thats awesome. Nice job Aaron!!!!!!!!!!!!!!!!!!
2Evil4U
03-20-2008, 08:16 PM
Damn Aaron! Do you think the extra weight will make it feel top heavy?

Well next time we ride I will count how many times the front stays down. Not like the big Buell motor needs any help lifting the front though.

Heh. With my mad riding skillz, I certainly won't be able to tell the difference. ;)

Hells Bells, I knocked the damn thing over in the garage while I was attaching the vent tube to the tank...:gay:

Wheelie-wise, the front of this baby stays firmly planted on the ground at all times now. A $210.50 "Careless Operation" fine will do that.

Truly, though, the total weight of the monstrosity with a full tank will only be about 35 pounds. Much less than a passenger, so I'm not too worried about it.
2Evil4U
03-20-2008, 08:20 PM
Further update. After additional thought, I'm not happy with my proposed design. Since there will always be fuel in the vent line as it is lower at some points than the top of the tank, I do not believe the fuel will flow as I want it to. Thinking about it more, I think that just the single hose I have connected to the vent at the top of the tank right now might work. It won't fill the tank if you start from empty with a closed cap, but if you start with a full tank, close the cap then fill the cell, it should suck the cell dry through the vent. I'm going to try that prior to drilling and tapping the drain plug hole. If it does work, I'll bump the vent hose from a 4AN to a 6AN to get better flow and call it a day.
Britton
03-21-2008, 05:49 PM
Looks good Aaron!!!
2Evil4U
03-23-2008, 08:11 PM
Well. I plugged all the remianing holes and filled the cell. It drained into the main tank fine (cap off). It was pretty slow, so I will probably bump the hose size from 1/4" id to 3/8" to get better flow.

I filled the main tank to the top, sealed it up and put about a gallon in the cell. Went out for a quick 110 mile loop from Zachary to Woodville and back and checked the fuel. No feed issues. The cell is totally empty and the main tank is almost full. I think I've got it.

And no leaks so far. I'm going to run this tank out to see how everything else work, then I'm going to re-plumb the feeder line and let 'er rip.
Britton
03-23-2008, 08:28 PM
SAAAWEEEETTTTT!!! Sounds like you've done a very good job! Congrats.
Bayou Boy
03-24-2008, 09:07 AM
I wouldn't worry about it flowing slow. If you turn on the petcock when the light turns on say it takes 10 minutes to drain. That's what, 12-13 miles at 80 mph. I would stick with smaller hose for ease in routing.
Check out the Long Distance forum on fjrforum.com they have all kinds of fuel cells.
2Evil4U
03-26-2008, 08:23 AM
did the first complete fill-up this morning. with the shape of the cell and the angle of the bike on the stand, it would only take about 3.4 gallons. so total is about 7.7-7.8 which should put it in the range of 320-340 miles to the idiot light that comes on with 0.6 gallons left. was kinda interesting paying $25 to fill the bike, though.
Fitty
03-26-2008, 01:18 PM
You gonna add one of these to it so your friends can "borrow" gas from you in the middle of the desert?

http://www.dualsportridersoflouisiana.com/photopost/data/500/nozzle.jpg
2Evil4U
03-26-2008, 02:08 PM
Hmmmmmm. I've got an extra outlet at the bottom of the cell. I could probably work up a Quick Disconnect fitting that would allow that to some extent... ;)
Shaq Diesel
03-27-2008, 10:46 PM
Is this for another Iron Butt attempt? It seems that the loss of a prime luggage spot would hinder you going too far away from home (more than a few days) at a time.
Bayou Boy
03-28-2008, 12:39 AM
It's on the passenger seat. He still has all three bags. How much crap do you need to take?
2Evil4U
03-28-2008, 08:24 AM
hell's bells. I can still put a full case of beer AND 2 10lb bags of ice in each side case. top case is for spare parts i'll inevitably break. what else do I need? :D
Britton
03-28-2008, 12:24 PM
Hey, if you're brining the beer, I'm in!!!
Fitty
03-28-2008, 02:10 PM
what else do I need? :D
Well, some new riding pants would be a good start. ;)
2Evil4U
04-06-2008, 03:13 PM
did the first complete fill-up this morning. with the shape of the cell and the angle of the bike on the stand, it would only take about 3.4 gallons. so total is about 7.7-7.8 which should put it in the range of 320-340 miles to the idiot light that comes on with 0.6 gallons left. was kinda interesting paying $25 to fill the bike, though.

I was pretty close. First full tanks was 328 miles to the idiot light. Just about 46 MPG. That oughta do it.
Swampy
04-06-2008, 06:37 PM
Thats about 100 miles more than I can go.
ONE LOVE
04-06-2008, 07:48 PM
Great ingenuity. Whats next?
allanj255
07-20-2011, 06:22 PM
Bump
How did it work out?
2Evil4U
07-20-2011, 06:38 PM
Hi Allen.

The aux tank worked out great. Never had a lick of problems with it even with total gravity feed. I ended up selling it to another Uly rider after I got the GSA.