Carrying Extra Fuel

[sparkyphotog]

I'm going to ride Canada and Alaska this summer with Calgary-Yogi, Moose, and DFW_Warrior. According to our official route manager, Yogi, we will be riding some sections of road where there is more than 200 miles between gas stations, so we are each coming up with a way to carry extra fuel. Yogi has attached plastic gas cans to his panniers on his Strom, Moose is going to install an auxiliary fuel cell that can feed straight into the fuel system on his R100 GS airhead, and I'm not sure what Bill's solution is yet. Here is mine.

Actually, this was going to be Moose's solution before he decided on the fuel cell, so he gave me these surplus jerry cans (http://www.cheaperthandirt.com/ZAA075-20712-1395.html)(5 liters each). Yogi had some left-over footman loops from his fuel can install, so I lucked out in acquiring the parts for this project - thanks guys! The installation was pretty easy, I just marked and drilled the holes where I needed to put a footman loop. I used 10-32 3/4 screws with nylon locking nuts and cap nuts, and 1 inch fender washers to secure each loop. To make it water resistant, I put a small bead of silicon under each fender washer. The handles on the jerry cans had to be cut so as not to interfere with the pannier lid latch. I purchased some straps with reflective material at REI for $3.50 each. to secure the cans. I just finished this today, and I haven't ridden the bike with extra fuel loaded yet, but I think this is going to work great. It gives me 2.6 extra gallons of gas, which should be more than enough for the extended sections of our trip. If you want more info on our planned ride, you can check out our web site at the URL in my sig.

http://sparkyphotog.smugmug.com/photos/286841911_crjVx-M.jpg

http://sparkyphotog.smugmug.com/photos/286842496_7GAqu-M.jpg

http://sparkyphotog.smugmug.com/photos/286843997_gbpLn-M.jpg

http://sparkyphotog.smugmug.com/photos/286844869_gJN5g-M.jpg

While I was at it, I also installed a water bottle rack to hold a MSR bottle. This will be used to carry extra engine oil.

http://sparkyphotog.smugmug.com/photos/286845381_ihf72-L.jpg

http://sparkyphotog.smugmug.com/photos/286845841_AQVAQ-M.jpg

http://sparkyphotog.smugmug.com/photos/286846313_uQye7-M-0.jpg

[dixonduke]

I like it alot! :thumb:

Now how are you going to secure the top box for the trip? :p

[sparkyphotog]

I like it alot! :thumb:

Now how are you going to secure the top box for the trip? :p

:rofl: :rofl: :rofl: I'm bringing an extra cargo net. :trust: That's how I secured it when it came off the first time.

[RedPill]

Looks like a good setup. Have you tested it with full cans over a rough course? Also, do you have anything cushioning the back of the cans from the panniers? That might be a good idea.

[jsb223]

Maybe some straps without the quick release buckles...

[dukey33]

Looks nifty.
don't forget to subtract the weight of the full cans from the capacity of the pannier racks.

Another piece of unsolicited advice. Fork gaiters.
A fellow on the Vulcan 500 group made the trip to Alaska and tore up his fork seals from all the mud crusted on the front of the fork tubes. He finished the trip, but the seals failed about a month after he got back.

[bones]

Nice work. That will be the trip of a lifetime! I am jealous as ever. :clap:

[sparkyphotog]

Looks like a good setup. Have you tested it with full cans over a rough course? Also, do you have anything cushioning the back of the cans from the panniers? That might be a good idea.

I'm going to glue some rubber drawer liner material to the cans - that will prevent metal-on-metal contact.

[sparkyphotog]

Maybe some straps without the quick release buckles...

I bought these because they have reflective material woven into them. I may get some without the quick release mechanism. There are two straps holding each can, so if one fails the other should hold it enough to keep me from losing it.

[sparkyphotog]

Nice work. That will be the trip of a lifetime! I am jealous as ever. :clap:

Thanks! How are things up north?

[sparkyphotog]

Another piece of unsolicited advice. Fork gaiters.
A fellow on the Vulcan 500 group made the trip to Alaska and tore up his fork seals from all the mud crusted on the front of the fork tubes. He finished the trip, but the seals failed about a month after he got back.

Not really an issue with the GS - the Telelever front suspension has a monoshock like the rear. The forks tubes provide no damping or shock absorption.

[RedPill]

I'm going to glue some rubber drawer liner material to the cans - that will prevent metal-on-metal contact.

That should work well, and will help keep the cans in the right position. Just having some friction between the pieces will take some of the load.

[bones]

Thanks! How are things up north?
Things are great other than no fun group of riders to hang with on Mondays :( and too short of riding season...hey but we have a million squids here just like you do :lol2:

[DaveC]

What supports the cans? I see the strap holds then in place. However nylon straps well wear through where they wrap around the corner. You may consider a angled aluminum small bracket to take the weight of the cans. Just a thought.

[bones]

Wow some of you really like to over engineer stuff. It's fine as is.

If you are worried, fill em with water and ride around for a while hit some rough roads and check it all out. My arm chair quarterback verdict is it's all fine. From there to Alaska there will be larger hurdles to cross than two gas cans falling off your hard cases.

[sparkyphotog]

What supports the cans? I see the strap holds then in place. However nylon straps well wear through where they wrap around the corner. You may consider a angled aluminum small bracket to take the weight of the cans. Just a thought.

The gas cans have rounded edges. Dopuble straps with probably 200 lb tensile strength. Maybe 10 pounds total weight for each can. I think it'll be fine.

[anaconda]

I like it! :clap:

[DFW_Warrior]

My bike is going to be sporting a 3.5gal tourtank mounted to the tail rack of the bike. It isn't going to be plumbed into the fuel system however, instead it will just have a dry break and a length of hose to aid in refueling duties.

[Moose]

Good Job Brian!

Once I get my new solo seat I'll get my fuel cell mounted and post up a couple pics

[Moose]

As promised a few pics of my set-up - 3 gal Summit racing dragster fuel cell on a custom rack. Motion pro quick disconnects and valve

http://boxermoose.smugmug.com/photos/309445968_wv6hh-M.jpg

http://boxermoose.smugmug.com/photos/309446173_S2Fdr-M.jpg

It worked out that the fuel valve and filter just sort of lay there and pass gas - I'm going to call that a "Honeymoon Fitting"
http://boxermoose.smugmug.com/photos/309524703_KMiqg-M.jpg

http://boxermoose.smugmug.com/photos/309524705_8PGco-M.jpg

gives me~90miles extra (the old airheads are not terribley fuel efficient) running 65-75 mph

[dixonduke]

Thanks for sharing Moose.... Looks GREAT!

Y'all are getting pretty close to leaving now I think. I am very jealous of the adventure y'all are bound to have.

GOOD LUCK!

[Moose]

Thanks!

'bout a weekand a half:eek2:



Thanks for sharing Moose.... Looks GREAT!

Y'all are getting pretty close to leaving now I think. I am very jealous of the adventure y'all are bound to have.

GOOD LUCK!

[rad3766]

Brian and Bruce,
Both aux. tanks look great, shouldnt be any issues. :clap:
Hope y'all have a safe journey.

[sparkyphotog]

Looks awesome, Moose! Nice work. :thumb: Have you ridden it yet?

[Moose]

Looks awesome, Moose! Nice work. :thumb: Have you ridden it yet?


Did that today (BTW there was a bad bike accident by Brazos bend SP - between the 2 sets of curves)

Flows enough fuel at 75mph which was my main worry. Holds 2.75gal with air space on top and got me just under 90 miles at fuel hungary speeds