[VetxSquared]

I love the idea and have been researching similar ideas on my own but kind of ran out of gas (sorry, bad pun) with all the roadblocks I was hitting (mainly my lack of knowledge).
Why not use the 17 gal tank though- it is shorter and carries two more gallons? Is it that the 30"x17" is too big?

 

[PhullD]

I love the idea and have been researching similar ideas on my own but kind of ran out of gas (sorry, bad pun) with all the roadblocks I was hitting (mainly my lack of knowledge).
Why not use the 17 gal tank though- it is shorter and carries two more gallons? Is it that the 30"x17" is too big?

The filler line position would be directly underneath the spare tire cross member, for two gallons it wasn't worh the work/complications.

 

[stockhardcore xterra]

Subscribed. Had the same thoughts but I have to get my rear bumper on and fab the tire carrier. Better to see how it goes for you and use your base of knowledge.

 

[PhullD]

Should have a parts list and price breakdown by this week.

 

[PhullD]

Update:

I put the project on hold due to some other costs that came up unrelated to the project. Will re-assess in October when some bills/costs etc have been dealt with.

Estimated build cost to order parts, mount tank, build the skid plate, wire gauge and pump switch, and plumb the filler into the driver's rear quarter panel was approximately 2600$ USD after taxes from a shop I go to (I brought my Corvette exclusively to this shop). That's with the Canadian markup costs, I imagine you Yanks could source the parts out for less. Also less if you make it a DIY project. I'm still on the fence about getting the parts and making this a winter project like I originally planned, but I have been so crazy busy I'm not sure it would get done (which is why I asked the shop to price it out for me).

This project will continue in some form or another in October so check back then!

 

[PhullD]

Update

Hello all, been putting this off. Recently we decided to have a full on wedding instead of a small city hall ceremony and a reception, so I don't really have the funds just yet to jump ahead with this project.

For those interested I found this 60L tank kit but have only found one distributor that would be willing to ship found here. This kit is for the D40 Navara but it is identical to the 2nd gen Frontier and judging by its position would be a good candidate for the Xterra. No need to re-locate your spare either, it tucks in behind the gas tank and underneath the exhaust and driveshaft (see attached images). This kit has the dual filler neck, all hardware, pump, etc. Essentially a complete kit (providing there are no discrepancies between the Frontier and Xterra in that location). Two negatives though, it is heavy (relatively speaking) and expensive. But like the saying goes cheap...easy...reliable pick two.

For those of us that don't have that kind of cash I am more looking at OEM tanks. The RCI tank was nice, but still has issues that I think can be solved in an OEM tank for a lot less than the 3000$ mark. However, apart from dimensions (approx max 33"x28"x12" with modifications) it is important to have the fill on the side, and a low profile up top where the pump and sending unit go. This way here you can tuck the tank up higher and order OEM components. The only catch is it has to be an electric pump as mechanical ones won't work with this setup. I've got a few candidates already: 1989 Geo Metro, 1983 Honda Civic, Geo Tracker (most years and Suzuki Pontiac and Chevy versions). This one is my favorite as of now due to the dimensions. I will have to modify the exhaust a little bit but it should be perfect.

 

[GeolJon]

^^
Interesting find. A little pricey, probably not on my radar, but definitely worth looking into.

 

[VMBiohazard]

If you do go this route, I'd be interested to see pics of the install and what all needed to be done to add in this option.

 

[PhullD]

This project is slowly awakening from its slumber. Found this 1995 F-150 gas tank which seems to be a bit wide in terms of width. Currently there is 29" or so without moving the exhaust, but I know there is room to move it and the edges can be pushed in slightly on these tanks. I don't think 5-6" of additional room would be too hard to achieve plus the tank is perfect in every other way such as side filler, side (relatively) mounted pump, under 8" thick and it has 69L capacity (we have 78L). All the parts are readily available for the F-150 too. For less than $100 you can get a plastic Dorman tank version for test fitting/plumbing. I'll update this when I find out more.

 

[caain]

Found this 1995 F-150 gas tank which seems to be a bit wide in terms of width.

I helped my dad put a new tank in one of his Mustangs last summer. We looked at a lot of different manufacturers and settled on one from Spectra Premium. Not the cheapest or most expensive by any means, but it seemed to be a well-built tank that was at least as good as the OEM had been.

 

[Nasarno]

Subscribed!

 

[Xterrorista']

Subscribed..

Gotta get the rear tire carrier on while you guys figure this out~

 

[Lowcountry idn]

For those interested I found this 60L tank kit but have only found one distributor that would be willing to ship found here. This kit is for the D40 Navara but it is identical to the 2nd gen Frontier and judging by its position would be a good candidate for the Xterra. No need to re-locate your spare either, it tucks in behind the gas tank and underneath the exhaust and driveshaft (see attached images). This kit has the dual filler neck, all hardware, pump, etc. Essentially a complete kit (providing there are no discrepancies between the Frontier and Xterra in that location). Two negatives though, it is heavy (relatively speaking) and expensive. But like the saying goes cheap...easy...reliable pick two.
.

So if anyone were interested in spending 3K on a tank, I am pretty sure this would not fit the Xterra anyway. I assume the Navara is similar to the Fronty - from the pic it looks the same - and there is a lot more room on my fronty between the rear axle and the factory tank than there is on My X, due to the longer wheelbase. It appears that way from the pic as well. So I am guessing it will not fit, at least from an initial look.

 

[PhullD]

So if anyone were interested in spending 3K on a tank, I am pretty sure this would not fit the Xterra anyway. I assume the Navara is similar to the Fronty - from the pic it looks the same - and there is a lot more room on my fronty between the rear axle and the factory tank than there is on My X, due to the longer wheelbase. It appears that way from the pic as well. So I am guessing it will not fit, at least from an initial look.

You may be right. My buddy's Frontier has been out of commission last few months so I haven't had the chance to measure the difference. Perhaps you can take the measurement?

I've got another tank that seems to be a good candidate. It's from a 2002 Chevy Blazer, unlike the Ford tank it doesn't require much if any exhaust modification. I'll update this when I have more details on fitment etc.

 

[Lowcountry idn]

You may be right. My buddy's Frontier has been out of commission last few months so I haven't had the chance to measure the difference. Perhaps you can take the measurement?

I've got another tank that seems to be a good candidate. It's from a 2002 Chevy Blazer, unlike the Ford tank it doesn't require much if any exhaust modification. I'll update this when I have more details on fitment etc.

The furthest back portion of the gas tank to the centerline of the rear axle is approximately 15.5 inches. In this 15.5 inches is also mounted the gas tank breather / carbon box / whatever its called. From the photo above it looks like they work around it - but I believe it could be relocated if needed. For reference that is a Crew Cab with 5 foot box.

Same space on the X is a few inches - maybe like 4 inches. The gas tank breather is behind the rear axle.

Consider these very rough measurements for illustrative purposes only.

 

[PhullD]

The furthest back portion of the gas tank to the centerline of the rear axle is approximately 15.5 inches. In this 15.5 inches is also mounted the gas tank breather / carbon box / whatever its called. From the photo above it looks like they work around it - but I believe it could be relocated if needed. For reference that is a Crew Cab with 5 foot box.

Same space on the X is a few inches - maybe like 4 inches. The gas tank breather is behind the rear axle.

Consider these very rough measurements for illustrative purposes only.

While I appreciate this, I am a visual person lol! I'll have to read it a couple times.

 

[Lowcountry idn]

While I appreciate this, I am a visual person lol! I'll have to read it a couple times.

Well, I could take some pictures but you already posted them in your post 46!

Youe top two photos - the OEM tank is that black thing in the top right corner of your photo's (which is the left side of the truck)

The white boxy portion of the aux tank right between the OEM tank and rear axle - that is what I am calling the 15.5 inches - actually its 15.5 inches to the centerline of the axle, so thats probably more like 13 inches of free space.

On the X you don't have any of that space. The OEM tank comes within a couple inches of the axle.

 

[Nasarno]

There are obvious clues that proves it's a Frontier not an Xterra. Leaf springs are on top of the axle. The big gap between axle and OEM gas tank does not exist on Xterra's short wheelbase. Evaporator canister is mounted inside the ladder frame, behind the wheel arch positioned toward the front of the car. A lot more if you dig into pictures.

Let me share my project and ask my critical questions in next posts.

 

[Nasarno]

I have already built (I didn't, my dear buddy and neighbor did) the extra gas tank to fit in the leftover space of the spare tire. Not to mention that I also benefit from 2" body lift. Per my measurements, it can hold something between 11 to 12 gallons. Not bad; it's still more than 2 jerry cans that people normally carry on their roof rack or tire carrier. I did not want to compromise on offroad-ability.

Here are some pictures of the tank. It's made of aluminum. You can see the side mounting spacers, 3 on each side. Top plate has a Z-shaped step to match the body line and use the maximum space available. Bottom plate is sloped forward. Filler, drain and breather pipes are not added yet.












I've cut the spare tire holder plate and mounting brackets are welded to the remainder of it on both sides, plus one to the round tube of the frame:



Passenger-side mounting bracket:



Driver-side mounting bracket:



Front bracket welded to frame's cross-pipe:



Thank mounted in place:

 

[Nasarno]

Now, time for the decision: how to fill it, and how to transfer the gas from it to main tank?

Let me ask the simple question first:
1- What happens when you overfill the OEM tank all the way to the filler neck? Does the gas goes into evaporator vent line and fills up the charcoal canister?
2- How the Gas station pump sensor detects the gas tank filled up and triggers the stopper?