Bulkhead fitting for aux tank through fuel pump?

I saw on a Beemer site a guy who installed his bulkhead fitting after cutting a hole in his fuel pump plate.

This seemed like a neat idea as cutting a hole in the tank is a bit concerning for noobs like me.

Any thoughts on doing something like this for my Gen1 FJR?

From the folks who have done this job, is there enough room to do this?

I have the aux tank set up ready to do, I am just hesitating on the tank hole.

Here is a link to what I'm referring to: https://www.davidebsmith.org/cycle/fuelcell/fuelcell.html

Your years of wisdom and expertise are greatly appreciated.

Thanks in advance,

-Brian

I think somebody tried it but I didn't do a good search for it. Putting a fitting in the tank is easier IMHO .

PM sent to frankenfeejeer.

Canadian FJR

PM sent to Canadian FJR

FJRay said:

I think somebody tried it but I didn't do a good search for it. Putting a fitting in the tank is easier IMHO .

Click to expand...

I did several searches and can't find where this has been attempted on an FJR.

Can you explain to a guy who hasn't takes his fuel tank apart, why it's easier? If nothing else, it seems there would be less of a chance of debris being left in the tank.

https://www.fjrforum.com/forum//index.php/topic/144111-appropriate-bulkhead-fitting-for-an-fjr-fuel-cell/?hl=+fuel%20+cell

https://www.fjrforum.com/forum//index.php?showtopic=111178&st=0&p=515258entry515258

For what it's worth, I've drilled two tanks. It took me a year to build up the courage to drill the first one. All in all, not a big deal. Just be careful when removing the fuel pump.

https://www.fjr1300.info/howto/bulkhead.html

Good luck.

Canadian FJR

FWIW, I had no luck getting the Sampson website, are they done?

I used this fitting:

https://www.aircraftspruce.ca/catalog/eppages/tankaccfitt.php?clickkey=212411

I replaced the o-rings that came with it with some tighter fitting ones I had on hand. So far so good.

I also used this same fitting to replace the supplied ANC outlets (outlet and vent) that came installed on the plastic Jeggs fuel cell. Not really happy with the quality of this tank. We'll see how it goes.

<blockquote class='ipsBlockquote'data-author="Canadian FJR" data-cid="1125985" data-time="1392385612"><p>

<a href='https://www.fjrforum.com/forum//index.php/topic/144111-appropriate-bulkhead-fitting-for-an-fjr-fuel-cell/?hl=+fuel%20+cell'>https://www.fjrforum.com/forum//index.php/topic/144111-appropriate-bulkhead-fitting-for-an-fjr-fuel-cell/?hl=+fuel%20+cell</a><br />

<br />

<a href='https://www.fjrforum.com/forum//index.php?showtopic=111178&st=0&p=515258entry515258'>https://www.fjrforum.com/forum//index.php?showtopic=111178&st=0&p=515258entry515258</a><br />

<br />

For what it's worth, I've drilled two tanks. It took me a year to build up the courage to drill the first one. All in all, not a big deal. Just be careful when removing the fuel pump.<br />

<br />

<a href='https://www.fjr1300.info/howto/bulkhead.html'>https://www.fjr1300.info/howto/bulkhead.html</a><br />

<br />

<br />

Good luck.<br />

<br />

<br />

<br />

Canadian FJR</p></blockquote>

A year sounds about right. Unfortunately I have about 30k of riding to do this year including a couple ss1k's, a bbg, a 50cc and ss3k to finish the year. I'm going to have to jump into it pretty quick!

Just take your time, think it through thoroughly and maybe drill a few sample holes first in scrap. It took me about a week to drum up enough nerve to drill my tank. I agree though that in the tank directly would be the best choice. Many have done it with much success. Use a step drill bit and go slow. Just don't forget which "step" you have to stop at.

It can be a PITA to get the pump out and back in, and depending on the size of your hand, an even bigger PITA to tighten up your bulkhead fitting. I chose not to weld my bulkhead on, but rather a threaded one w/ nut.

Best of luck to you on this as well as on your summer trips. Sounds like fun.

Here's my blog of when I tapped my tank..

Thanks for the replies. I have seen many examples and how-tos for getting the tank drilled. I understand that's doable and seems to be the preferred method.

My question was why not drill into the fuel pump plate instead of the tank. Is there room enough to do this on the plate? Is there a reason everyone chooses to drill the tank, other than the quarter shaped space that seems made for it?

Thanks

frankenfeejeer said:

Thanks for the replies. I have seen many examples and how-tos for getting the tank drilled. I understand that's doable and seems to be the preferred method.My question was why not drill into the fuel pump plate instead of the tank. Is there room enough to do this on the plate? Is there a reason everyone chooses to drill the tank, other than the quarter shaped space that seems made for it?

Thanks

Click to expand...

When I did my tank I knew that some people had figured out how to go through the fuel pump plate. But I never felt comfortable with that idea. The fuel pump on the inside of the tank takes more space on the plate than you might think. In the end I was just never comfortable with the idea.

If I might make another suggestion. When I did my tank originally I was going to drill the tank myself. However I was able to find a local welder who took care of it for me for just $20. I brought the tank in (fuel pump removed) with an X marking the spot. Picked it up a couple days later with a 1/4 NPT threaded fitting welded on.

What you need to do is find a guy that knows his stuff. Turns out my welder has developed a good deal of experience fixing expensive Harley gas tanks. I guess the mounting tangs on the back have a habit of breaking off due to vibration. He is able to properly control the heat so he can weld that tang back on without damaging the paint on the front. The fitting welded onto my tank was about 1-2 inches from the edge of the bottom. Not a spec of heat damage anywhere on the paint!

Just a thought

- Colin

frankenfeejeer said:

Thanks for the replies. I have seen many examples and how-tos for getting the tank drilled. I understand that's doable and seems to be the preferred method.My question was why not drill into the fuel pump plate instead of the tank. Is there room enough to do this on the plate? Is there a reason everyone chooses to drill the tank, other than the quarter shaped space that seems made for it?

Thanks

Click to expand...

It's been awhile, but as I recall it would be really difficult to put the bulkhead connector into the fuel pump. I would be carefull when attempting to do the same thing on a FJR as on a BMW. the BMW fuel tanks extend far lower than the FJR does. When you are using gravity to transfer the fuel you can use a much smaller hose and fitting size than you can when the Aux. tank and main are close to the same level. If you have a 48 state bike and use 1/4" hose it will transfer fuel very slowly, and when it is hot or at altitude, maybe not at all. It will work better with 3/8" or larger hose. If you have a California model it doesn't matter because the vapor recovery system creates suction in the fuel tank and helps transfer the fuel.