Fuel Cells

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Planning another season of long distant motorcycling we decided we needed to extend our range. The Honda GL1800 Goldwing in stock form is only good for about 250miles at most. The Ironbutt Assoociation allows up to 11.5 gallons of fuel with a fuel cell. The stock motorcycle fuel tank is 6.5 gallons.

We wanted something cheap and simple. It didn't need to be pretty but functional. We decided a Jaz Fuel cell with gravity feed to the main tank was the best option. The tanks are mounted on 10gauge steel sheet that has been cut and bent to make a mount. The 1/4" fuel hose I used is easy for routing but I would recommend going larger to increase drain rates. It takes about 15-20minutes for the cell to drain into the main tank.

Parts
Click here for an Excel spreadsheet containing a parts list.

We ordered many parts over the internet and bought some locally. See the above parts list. One word of caution. I ordered the quick disconnects, ball valves, and bulkhead fittings from Sampson Sport Touring. It took them over 45days to get the parts to me. Plus they charged me $100 shipping for a 2# UPS ground shipment and a 1# USPS priority mailer. One of the bulkhead fittings was missing parts on top of it all. They claimed they would refund shipping to actual cost +15% but I have not seen any money back from them. I would recommend getting parts from McMaster Carr or another source instead.

Click the thumbnails to enlarge

Honda Goldwing GL1800 fuel cell construction

Template is made out of cardboard. The misc. tabs keep the fuel cell in place and allow a backrest to be mounted.	Jaz fuel cell on template	The cardboard was test fitted on the bike. (no picture)	The 10gauge sheet ready for cutting. Only 30cents per lb.

Tracing the template		Pilot holes were drilled to make cutting easier at the corners. Strips were also cut out of the middle of the bending lines to make bending easier.	The cheap $30 jigsaw was overheating trying to cut the steel. A blast of Minnesota 0degree air didn't help.

It eventually failed.	Enter the $70 jigsaw!	Using a 12tooth/inch Bi-metal blade made short work of the cutting.	Cutting complete.

We eventually widened the relief cuts at the bending location since the steel was so stiff.	Using a vice and mallet the metal was bent to the desired shape.	A test fit. Notice the trunk will not open entirely with the passenger backrest in place.	The psgr backrest is held in place by 2 screws and sliding tabs. The screws will be left out and replace by velcro when the tank is in on the bike.

When full trunk access is needed the psgr backrest will be removed.	The next step will be cutting any unnecessary corners and grinding down all the edges and prepping for paint.	The frame will be attached to the handles with u-bolts.	Test fitting a ratcheting strap. The whole setup is solid.

another angle	Only the plumbing is left	A backrest slides over the front tabs	Backrest in place. It can slide vertically for adjustment

I took the fuel level sending plate off.	Drilled a hole in a strategic location for the bulkhead fitting	There aren't many places where it can go.	Make sure you select carefully.

Installed bulkhead fitting	more views	more	more

Its very close to the bar which the seat hooks onto	The hook on the seat needed to be trimmed.	An Alternate location is here. This is really a tight fit but you don't need to modify the seat.	The hose was routed inside the frame with secondary ball valve and quick disconnect.

top view.	The hose comes outside of the plate.	Finished. Don't forget the ground wire and a vent hose.

The lower fuel sender..	and pump with filter.	This is just for reference. You don't need to dig in here.
BMW R1100RT fuel cell and highway peg construction

The fuel cell mount was constructed the same way on the RT	Extra holes were drilled in the sides to carry other things on side mounts	The cell mount coated and mounted.	Since the front seat is usually held down by the back, a pivoting brace was used.

Carrie wanted highway pegs. Here is the model of the bracket	Cutting the bracket. Door stopper is the folding peg.	The tank was drained and removed. The plate is the where we will drill through	The guts of an RT

More guts...	and more..	Here you can see the $10 highway pegs completed. Door stops drilled and tapped to limit forward movement.	The plate was drilled.

Bulkhead fitting inserted.	Here you can see the inside.	The hose was routed with the stock fuel lines.	Then under the seat with a quick disconnect and ball valve.

The finished product with valve in easy reach. The rails on the side will hold containers for on the road storage.