While trying to figure out a permanent solution for a receiver hitch platform (swing away required to keep the rear door functional) to carry extra fuel, which would also require at least an 8" rise to keep the FJ trail worthy, I had an epiphany!
First, I'm too old and crippled to be loading full 5 gallon jerry cans onto the roof. So I would have to load a bunch of wee 2-3 gallon cans, and the more pieces there are to secure, the more likely one or more will work their way loose during transit or during off road rocking and rolling.
Having resigned myself to throwing a trio of new 5 gallon cans into the back of the FJ, then filling them up and wrestling them onto the roof once we reach the Big Bend area, I was still concerned with untested cans leaking all over the place. That's when the little light bulb centered above my cranium suddenly came to light.
What fuel can is almost 100% guaranteed to NOT leak under expansion and use? Out of the perhaps 100 fuel cans I've owned in my life, there was only one type that rarely leaked, and almost never turned over upon its side to increase the leak rate: MARINE FUEL TANKS!
Yep, the old outboard fuel tanks were BUILT for rough service, and a LOW profile! So I checked them on the Bass Pro Shops website. These tanks are built to withstand serious internal pressure, too. They have to pass far stricter standards of performance than simple fuel cans.
So, here's the system:
1. Two Moeller 9 GALLON Poly Tanks (29.50"L x 13.75"W x 10"H), mounted laterally at the rearmost position upon within the roof rack. One additional roof rack slat will be moved rearward to aid in weight distribution. Eighteen gallons will weigh no more than 120 pounds (within the 154 pound limit of the rack). However, I will probably only put 8 gallons in each tank in order to have a safety margin for big 'bumps'. Each tank will be positioned to have the 10"X13.75" side faced forward (fill caps to the rear).
Moeller Marine Products Topside Fuel Tanks - Medium Standing on the rear bumper, I should easily be able to fill each tank without spilling. Each tank DOES have a sight fuel gauge.
2. A tank connector will be required for the tank's NPT fitting:
Bass Pro Shops Marine Fuel Line and Tank Connectors for Johnson/Evinrude Though the size of the fitting is rather small, refueling in the back country should not be a hurried process. As long as one watches the fuel gauge/odometer, then there should be little or no chance of 8-9 gallons causing an overflow at the FJ tank.
3. A self priming hose with a fuel tight connection is required. Again, this is common in the small boat industry:
Bass Pro Shops Fuel Line Assembly for Johnson/Evinrude Motors This is likely to require the addition of the fitting listed at #2 above in order to overcome the sealing of the disconnect feature of this self pressurized squeeze bulb. But once the siphon is going, it should continue upon its own. (I'd be glad to hear from those that are more familiar with this marine application than I am.)
4. Strapped in between these two tanks will be a small, cheap, plastic ice chest (6 pack sized) so that I can store the contaminated 7' fuel line inside it between fuelings.
If you checked the links, you'll see that less the cost of straps to secure the tanks, the total cost for relatively safe off road extra fuel is going to be around $130.00, including tax!
If I'm getting just 10mpg off road, then the 16 gallons of roof rack fuel combined with 19 gallons of OEM fuel tank ought to get me at least 350 miles. Granted, this isn't a set up for timed events or racing (refueling will be rather slow), but it should be pretty safe, EASY, and not cost an arm and a leg. But then, I'm not the brightest person around. I used to carry a nearly a dozen 1qt canteens on a motorcycle and refuel at highway speeds.
So you guys let me know if I'm off center here....
Otherwise, they could bring over their empty containers and I'd fill them at the rear of my FJ. Of course I'm have never been too patient with those who 'run out of gas'. They are usually mooches who don't pay their own way, although there have been one or two who blew a fuel line, holed a fuel tank, or cracked a fuel filter and ran low before they knew it. I don't mind helping those victimized by such things. But those who run all weekend then start bumming gas...well, they need to 'walk out' a time or two in order to learn how to budget their fuel better! LOL...
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