Tom Melchild's Fuel Cell

Tom Melchild installed an auxillary fuel cell on his Yamaha FJR1300,
and sent in these photos on 11/16/02:

I finally got done installing the fuel cell this week, and took it on a little 700 mile test ride. Warchild was right, T'ing into the return line didn't work. I had to drill a 1/2" hole in the bottom of the tank and install a bulkhead connector. I used 3/8" fuel line to go from the aux. cell to the main tank. I have a small stainless steel ball valve to turn the flow on and off. I also installed a quick connect fitting so I can disconnect it when I remove the cell.

I mounted the cell using the two 6mm allen bolts under the passenger seat that hold the grab rail on, and the bolt in the center of the luggage rack. I made the rack so I can put the passenger seat on under the cell. It looks real clean, and I can remove/install the cell and rack in about 2 minutes.

It works real nice. If I run the main tank down about a bar and half, (about 70 miles) I can turn the aux. cell valve on and leave it on. It does not overflow the main tank. It goes about 270 before the gauge goes down 2 bars. The first tank I went on reserve at 425 miles. That is cruising at about 80-90 mph down I5, and running throught the twisties on Hwy 33 down to Ojai.

To make sure I don't violate the Iron Butt Assn. rules of 11.5 gallons, I put a short brass extension on the drain connection in the tank so it does not drain the bottom 1/2 inch of fuel. Filling the cell from empty took 4.85 gallons. With the main tank at 6.6, that puts me at total of 11.45 gallons.